Disposable absorbent article with absorbent particulate polymer material distributed for improved isolation of body exudates

ABSTRACT

A disposable absorbent article is provided having an absorbent core located in a chassis and including absorbent particulate polymer material defining at least one cavity for improved isolation of fecal matter or other body exudates. The absorbent core may be substantially cellulose free. Methods for making such an absorbent core and corresponding disposable absorbent article are also disclosed.

FIELD OF THE INVENTION

The present invention generally relates to an absorbent article, andmore particularly to a disposable absorbent garment, such as a tapeddiaper or training pant, comprising absorbent particulate polymermaterial.

BACKGROUND OF THE INVENTION

Absorbent articles, such as disposable diapers, training pants, andadult incontinence undergarments, absorb and contain body exudates.

Fecal material is often difficult to remove from the skin of the user(e.g., wearer) of the absorbent article, in particular on sensitive skinsuch as that of young babies. Moreover, it is known that fecal materialon the skin can cause irritation and redness of the skin and sometimeseven dermatitis. Hence it desirable to reduce the fecal material on theskin, to provide a means to isolate the fecal material immediately afterdischarge, away from the skin. Conventional approaches toward thisisolation include providing a diaper with a top sheet with one or moreopenings, through which the feces can pass for storage underneath thistop sheet, away from the skin. However, this approach may not always beeffective, particularly when the baby is in a sitting position or whenthe diaper is already highly urine-loaded, both of which diminish thevoid volume available to receive the feces.

There is also a desire to improve the comfort and fit of absorbentarticles such as diapers, for example to make them thinner and moreflexible while preserving or enhancing the article's ability to absorband hold one or more gushes of liquid, to minimize uncontrolled bowelmovement spreading, and to capture bowel movements so as to lead tocleaner skin for the wearer, with consequently less skin irritation andeasier clean up.

SUMMARY OF THE INVENTION

The present invention addresses one or more technical problems describedabove and provides a disposable absorbent article, which may comprise achassis and an absorbent core, which may be substantially cellulosefree. The chassis may include a top sheet and a back sheet. Theabsorbent core may be located between the top sheet and the back sheetand may comprise an absorbent particulate polymer material. Theabsorbent core includes at least one cavity, which may be defined atleast about its perimeter by the absorbent particulate polymer material.The at least one cavity may be substantially free of the absorbentparticulate polymer material. In one embodiment, the void volume of thecavity may be from about 2 ml to about 70 ml.

In one embodiment, the absorbent particulate polymer material present inthe absorbent core may have a basis weight that varies across theabsorbent core in a direction substantially perpendicular to the centrallongitudinal axis, in a direction substantially parallel to the centrallongitudinal axis, or in both directions.

In one embodiment, the disposable absorbent article may have a centrallongitudinal axis extending from a first end to a second end, and the atleast one cavity may include (i) a first channel elongated in adirection substantially parallel to and located about the centrallongitudinal axis, and (ii) a second channel elongated in a directionsubstantially perpendicular to the central longitudinal axis. The firstand second channels of the cavity together may form a T-shape.

In certain embodiments, the first channel may have a width from about 5%to about 60% of the width of the absorbent core and a length from about2% to about 50% of the length of the absorbent core. The second channelmay have a width from about 25% to about 90% of the width of theabsorbent core and a length from about 2% to about 40% of the length ofthe absorbent core. In one embodiment, the first channel of the cavitymay have a width between about 10 mm and about 40 mm, and a lengthbetween about 10 mm and about 130 mm. In another embodiment, the secondchannel of the cavity may have a width between about 30 mm and about 110mm, and a length between about 10 mm and about 100 mm. Combinations ofthe first and second channels with these dimension ratios and values arecontemplated.

In one embodiment, the absorbent core may comprise a core cover and adusting layer adhered to one another about the periphery of theabsorbent core to form an envelope about the absorbent particulatepolymer materials to hold the absorbent particulate polymer materialwithin the absorbent core. The core cover and the dusting layer may beadhered to one another about an area defining the bottom of the at leastone cavity.

In one embodiment, the disposable absorbent article may further includean acquisition system located between the absorbent core and the topsheet. In one embodiment, the acquisition system may include an upperacquisition layer, which faces the top sheet, and a lower acquisitionlayer, which faces the absorbent core. In one case, the loweracquisition layer does not cover the at least one cavity. In one case,the upper acquisition layer does not completely cover the at least onecavity. The at least one cavity may further be defined about itsperimeter by interior edges of an aperture in the acquisition system.

In a certain embodiment, the top sheet of the disposable absorbentarticle is an elasticized top sheet having at least one opening. Atleast a portion of the opening may be substantially aligned with thefirst channel of the cavity in the absorbent core.

In certain embodiments, the disposable absorbent article may be a diaperor a pant. In one example, the first channel of the cavity is located inthe absorbent core along the central longitudinal axis of the diaper orpant at a position which, when the diaper or pant is worn by a wearer,will be in alignment with a predetermined region about the anus of thewearer.

In another aspect, a method is provided for making an absorbent core foruse in a disposable absorbent article. The method may comprisedepositing an absorbent particulate polymer material on a firstsubstrate to form an absorbent core having a central longitudinal axisextending from a first end to a second end, such that the absorbent coreis substantially cellulose free and comprises at least one cavitydefined at least about its perimeter by the absorbent particulatepolymer material. The at least one cavity may be substantially free ofabsorbent particulate polymer material.

In one embodiment, the step of depositing may comprise placing the firstsubstrate on a porous forming surface and depositing the absorbentparticulate polymer material to the substrate while applying a vacuum tothe substrate through the porous forming surface. In one example, theforming surface may have recesses for receiving the substrate and theabsorbent particulate polymer material and the recesses may be sized andarranged to vary the basis weight of the absorbent particulate polymermaterial across the substrate. In another example, the vacuum applied tothe substrate may vary across the forming surface so as to vary thebasis weight of the absorbent particulate polymer material across thesubstrate.

In another embodiment, the step of depositing may further comprisepneumatically delivering the absorbent particulate polymer material tothe substrate and varying the pneumatic delivery to the forming surfaceso as to vary the amount of absorbent particulate polymer materialacross the substrate. In one embodiment, the method may further includeadhering the first substrate to a second substrate about theirperipheries to form an envelope about the absorbent particulate polymermaterial to hold the absorbent particulate polymer material within theabsorbent core.

In one embodiment, the first substrate and the second substrate may beadhered to one another about an area defining the bottom of the at leastone cavity. In one embodiment, the at least one cavity may be stampedinto the absorbent core.

In still another aspect, a method is provided for making a disposableabsorbent article. The method may comprise depositing an absorbentparticulate polymer material on a substrate to form an absorbent corewhich is substantially cellulose free; forming at least one cavity inthe absorbent core, said at least one cavity being defined at leastabout its perimeter by the absorbent particulate polymer material ; andlocating the absorbent core between a top sheet and a back sheet of achassis. In one embodiment, the method may further include adhering acore cover and a dusting layer to one another about a periphery of theabsorbent core to form an envelope about the absorbent particulatepolymer materials to hold the absorbent particulate polymer materialwithin the absorbent core. In one case, the method may further includeadhering the core cover and the dusting layer to one another at an areaabout the bottom of the at least one cavity. In one embodiment, themethod may further include locating an acquisition system between thetop sheet and the absorbent core.

Features and advantages of the invention may be apparent from thefollowing detailed description, drawings, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a diaper in accordance with an embodiment ofthe present invention.

FIG. 2 is a cross sectional view of the diaper shown in FIG. 1 takenalong the sectional line 2-2 of FIG. 1.

FIG. 3 is a partial cross sectional view of an absorbent core layer inaccordance with an embodiment of this invention wherein more absorbentparticulate polymer material is present toward lateral edges of thediaper than in a central zone of the diaper.

FIG. 4 is a partial cross sectional view of an absorbent core layer inaccordance with another embodiment of this invention.

FIG. 5 is a plan view of the absorbent core layer illustrated in FIG. 3.

FIG. 6 is a plan view of a second absorbent core layer in accordancewith an embodiment of this invention wherein more absorbent particulatepolymer material is present toward lateral edges of the diaper than in acentral zone of the diaper.

FIG. 7 is a partial sectional view of an absorbent core comprising acombination of the first and second absorbent core layers illustrated inFIGS. 5 and 6.

FIG. 8 is a plan view of the absorbent core illustrated in FIG. 7.

FIG. 9 is a plan view of an absorbent core wherein more absorbentparticulate polymer material is present toward ends of the diaper thanin a central zone of the diaper.

FIG. 10 is a plan view of an absorbent core wherein more absorbentparticulate polymer material is present toward lateral edges and ends ofthe diaper than in a central zone of the diaper.

FIG. 11 is a plan view of an absorbent core in accordance with anembodiment of the present invention.

FIG. 12 is a cross-sectional view, taken along line 12-12 of theabsorbent core illustrated in FIG. 11.

FIG. 13 is a perspective view of an absorbent article in accordance withan embodiment of the present invention, including an elasticized topsheet having an opening for receiving fecal matter.

FIG. 14 is a cross-sectional, perspective view of the absorbent articleillustrated in FIG. 13.

FIG. 15 is a schematic representation of a rheometer.

FIG. 16 is a schematic illustration of a process for making an absorbentcore in accordance with an embodiment of this invention.

FIG. 17 is a partial sectional view of an apparatus for making anabsorbent core in accordance with an embodiment of this invention.

FIG. 18 is a perspective view of the printing roll illustrated in FIG.17.

FIG. 19 is a partial sectional view of the printing roll illustrated inFIG. 18 showing absorbent particulate polymer material reservoirs.

FIG. 20 is a perspective view of the supporting roll illustrated in FIG.16.

FIG. 21 is a perspective view of a printing roll for making an absorbentcore wherein more absorbent particulate polymer material is presenttoward ends of the diaper than in a central zone of the diaper.

FIG. 22 is a partial sectional view of the printing roll illustrated inFIG. 21 showing absorbent particulate polymer material reservoirs.

FIG. 23 is a perspective view of a printing roll for making an absorbentwherein more absorbent particulate polymer material is present towardlateral edges and ends of the diaper than in a central zone of thediaper.

FIG. 24 shows plan views of twenty different absorbent cores withdifferent possible geometric designs of cavities, according to certainembodiments of the invention.

FIGS. 25A-C are cross-sectional views of various constructions of acavity in an absorbent core, according to certain embodiments of theinvention.

FIGS. 26A-C are cross-sectional views (FIGS. 26A-B) and a plan view(FIG. 26C) of various constructions of a cavity defined, at least inpart, by an acquisition system, according to another embodiment of theinvention.

FIGS. 27A-K are plan views of several absorbent cores having cavitiesand different acquisition system designs, according to certainembodiments of the invention.

FIG. 28A is a plan view and FIG. 28B is a cross-sectional view, takenalong sectional line B-B, of an absorbent core having a gradient ofabsorbent particulate polymer material around the cavity and anacquisition layer which augments the cavity, according to one embodimentof the invention.

DETAILED DESCRIPTION OF THE INVENTION

A disposable absorbent article has been developed which comprises achassis, which may include a top sheet and a back sheet, and anabsorbent core which may be located between the top sheet and the backsheet and may comprise an absorbent particulate polymer material. Theabsorbent core may include one or more cavities, for accommodating abowel movement, defined at least about its perimeter by the absorbentparticulate polymer material redistributed (versus cavity-less core)whilst maintaining overall liquid containment capacity. In a certainembodiment, the disposable absorbent article may have a centrallongitudinal axis extending from a first end to a second end, and thecavity may include (i) a first channel elongated in a directionsubstantially parallel to and located about the central longitudinalaxis, and (ii) a second channel elongated in a direction substantiallyperpendicular to the central longitudinal axis. The disposable absorbentarticle optionally may further include an elasticized top sheet locatedadjacent the top sheet and having at least one opening, a portion ofwhich may be substantially aligned with the first channel of the cavityin the absorbent core. Embodiments of such disposable absorbent articlesare described hereinbelow along with embodiments of apparatuses andmethods for making such disposable absorbent articles.

Definitions

“Absorbent article” refers to devices that absorb and contain bodyexudates, and, more specifically, refers to devices that are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Absorbent articles mayinclude diapers, training pants, adult incontinence undergarments,feminine hygiene products, breast pads, care mats, bibs, wound dressingproducts, and the like. As used herein, the term “body fluids” or “bodyexudates” includes, but is not limited to, urine, blood, vaginaldischarges, breast milk, sweat and fecal matter.

“Absorbent core” means a structure typically disposed between a topsheet and cover sheet of an absorbent article for absorbing andcontaining liquid received by the absorbent article and may comprise oneor more substrates, absorbent polymer material disposed on the one ormore substrates, and a thermoplastic composition on the absorbentparticulate polymer material and at least a portion of the one or moresubstrates for immobilizing the absorbent particulate polymer materialon the one or more substrates. In a multilayer absorbent core, theabsorbent core may also include a cover layer. The one or moresubstrates and the cover layer may comprise a nonwoven. Further, theabsorbent core may be substantially cellulose free. The absorbent coredoes not include an acquisition system, a top sheet, or a back sheet ofthe absorbent article. In a certain embodiment, the absorbent core wouldconsist essentially of the one or more substrates, the absorbent polymermaterial, the thermoplastic composition, and optionally the cover layer.In another embodiment, the amount of absorbent particulate polymermaterial present in the absorbent core may vary across the absorbentcore.

“Absorbent polymer material,” “absorbent gelling material,” “AGM,”“super absorbent,” and “super absorbent material” are used hereininterchangeably and refer to cross linked polymeric materials that canabsorb at least 5 times their weight of an aqueous fluid such as 0.9%saline as measured using the Centrifuge Retention Capacity test.“Absorbent particulate polymer material” is used herein to refer to anabsorbent polymer material which is in particulate form so as to beflowable in the dry state.

“Airfelt” is used herein to refer to comminuted wood pulp, which is aform of cellulosic fiber.

“Basis weight” means weight of a material per unit area of the material.

“Comprise,” “comprising,” and “comprises” are open ended terms, eachspecifies the presence of what follows, e.g., a component, but does notpreclude the presence of other features, e.g., elements, steps,components known in the art, or disclosed herein.

“Consisting essentially of” is used herein to limit the scope of subjectmatter, such as that in a claim, to the specified materials or steps andthose that do not materially affect the basic and novel characteristicsof the subject matter.

“Disposable” is used in its ordinary sense to mean an article that isdisposed or discarded after a limited number of usage events overvarying lengths of time, such as less than about 20 events, or less thanabout 10 events, or less than about 5 events, or less than about 2events.

“Diaper” refers to an absorbent article generally worn by infants andincontinent persons about the lower torso so as to encircle the waistand legs of the wearer and that is specifically adapted to receive andcontain urinary and fecal waste. As used herein, term “diaper” alsoincludes “pants” which is defined below.

“Fiber” and “filament” are used interchangeably.

“Hydrophilic” describes fibers or surfaces of fibers, which are wettableby aqueous fluids (e.g. aqueous body fluids) deposited on these fibers.Hydrophilicity and wettability are typically defined in terms of contactangle and the strike through time of the fluids, for example through anonwoven fabric. This is discussed in detail in the American ChemicalSociety publication entitled “Contact angle, wettability and adhesion”,edited by Robert F. Gould (Copyright 1964). A fiber or surface of afiber is said to be wetted by a fluid (i.e. hydrophilic) when either thecontact angle between the fluid and the fiber, or its surface, is lessthan 90°, or when the fluid tends to spread spontaneously across thesurface of the fiber, both conditions are normally co-existing.Conversely, a fiber or surface of the fiber is considered to behydrophobic if the contact angle is greater than 90° and the fluid doesnot spread spontaneously across the surface of the fiber.

A “nonwoven” is a manufactured sheet, web or batt of directionally orrandomly orientated fibers, bonded by friction, and/or cohesion and/oradhesion, excluding paper and products which are woven, knitted, tufted,stitch-bonded incorporating binding yarns or filaments, or felted bywet-milling, whether or not additionally needled. The fibers may be ofnatural or man-made origin and may be staple or continuous filaments orbe formed in situ. Commercially available fibers have diameters rangingfrom less than about 0.001 mm to more than about 0.2 mm and they come inseveral different forms: short fibers (known as staple, or chopped),continuous single fibers (filaments or monofilaments), untwisted bundlesof continuous filaments (tow), and twisted bundles of continuousfilaments (yarn). Nonwoven fabrics can be formed by many processes suchas meltblowing, spunbonding, solvent spinning, electrospinning, andcarding. The basis weight of nonwoven fabrics is usually expressed ingrams per square meter (gsm).

“Pant” or “training pant”, as used herein, refer to disposable garmentshaving a waist opening and leg openings designed for infant or adultwearers. A pant may be placed in position on the wearer by inserting thewearer's legs into the leg openings and sliding the pant into positionabout a wearer's lower torso. A pant may be preformed by any suitabletechnique including, but not limited to, joining together portions ofthe article using refastenable and/or non-refastenable bonds (e.g.,seam, weld, adhesive, cohesive bond, fastener, etc.). A pant may bepreformed anywhere along the circumference of the article (e.g., sidefastened, front waist fastened). While the terms “pant” or “pants” areused herein, pants are also commonly referred to as “closed diapers,”“prefastened diapers,” “pull-on diapers,” “training pants,” and“diaper-pants”. Suitable pants are disclosed in U.S. Pat. No. 5,246,433,issued to Hasse, et al. on Sep. 21, 1993; U.S. Pat. No. 5,569,234,issued to Buell et al. on Oct. 29, 1996; U.S. Pat. No. 6,120,487, issuedto Ashton on Sep. 19, 2000; U.S. Pat. No. 6,120,489, issued to Johnsonet al. on Sep. 19, 2000; U.S. Pat. No. 4,940,464, issued to Van Gompelet al. on Jul. 10, 1990; U.S. Pat. No. 5,092,861, issued to Nomura etal. on Mar. 3, 1992; U.S. Patent Publication No. 2003/0233082 A1,entitled “Highly Flexible And Low Deformation Fastening Device”, filedon Jun. 13, 2002; U.S. Pat. No. 5,897,545, issued to Kline et al. onApr. 27, 1999; U.S. Pat. No. 5,957,908, issued to Kline et al on Sep.28, 1999.

“Substantially cellulose free” is used herein to describe an article,such as an absorbent core, that contains less than about 10% by weightcellulosic fibers, less than about 5% cellulosic fibers, less than about1% cellulosic fibers, no cellulosic fibers, or no more than animmaterial amount of cellulosic fibers. An immaterial amount ofcellulosic material would not materially affect the thinness,flexibility, or absorbency of an absorbent core.

“Substantially continuously distributed”, as used herein, refers toabsorbent particulate polymer material that is arranged across theabsorbent particulate polymer material area. Optionally, the absorbentparticulate polymer material may be arranged such that the substratelayers do not touch in zones 122 and 124. In one embodiment, thesubstrate layers may touch in the peripheral areas outside the absorbentparticulate polymer material area. It is important to note that thethermoplastic material used in the presently described disposableabsorbent articles does not interrupt the substantially continuouslydistributed absorbent particulate polymer material. Thus, thesubstantially continuously distributed absorbent particulate polymermaterial includes the thermoplastic material.

“Substantially free of absorbent particulate polymer material”, as usedherein, refers to the one or more cavities of the absorbent core havingan area (in plan view) in which the absorbent particulate polymermaterial is present in an amount not exceeding 10% of the basis weightof absorbent particulate polymer material in the area of the absorbentcore surrounding the one or more cavities.

“Thickness” and “caliper” are used herein interchangeably.

Absorbent Articles

FIG. 1 is a plan view of a diaper 10 according to a certain embodimentof the present invention. The diaper 10 is shown in its flat out,uncontracted state (i.e., without elastic induced contraction) andportions of the diaper 10 are cut away to more clearly show theunderlying structure of the diaper 10. A portion of the diaper 10 thatcontacts a wearer is facing the viewer in FIG. 1. The diaper 10generally may comprise a chassis 12 and an absorbent core 14 disposed inthe chassis.

The chassis 12 of the diaper 10 in FIG. 1 may comprise the main body ofthe diaper 10. The chassis 12 may comprise an outer covering 16including a top sheet 18, which may be liquid pervious, and/or a backsheet 20, which may be liquid impervious. The absorbent core 14 may beencased between the top sheet 18 and the back sheet 20. The chassis 12may also include side panels 22, elasticized leg cuffs 24, and anelastic waist feature 26.

The leg cuffs 24 and the elastic waist feature 26 may each typicallycomprise elastic members 28. One end portion of the diaper 10 may beconfigured as a first waist region 30 of the diaper 10. An opposite endportion of the diaper 10 may be configured as a second waist region 32of the diaper 10. An intermediate portion of the diaper 10 may beconfigured as a crotch region 34, which extends longitudinally betweenthe first and second waist regions 30 and 32. The waist regions 30 and32 may include elastic elements such that they gather about the waist ofthe wearer to provide improved fit and containment (elastic waistfeature 26). The crotch region 34 is that portion of the diaper 10which, when the diaper 10 is worn, is generally positioned between thewearer's legs.

The diaper 10 is depicted in FIG. 1 with its central longitudinal axis36 and its transverse axis 38. The periphery 40 of the diaper 10 isdefined by the outer edges of the diaper 10 in which the longitudinaledges 42 run generally parallel to the longitudinal axis 36 of thediaper 10 and the end edges 44 run between the longitudinal edges 42generally parallel to the transverse axis 38 of the diaper 10. Thechassis 12 may also comprise a fastening system, which may include atleast one fastening member 46 and at least one stored landing zone 48.

The diaper 10 may also include such other features as are known in theart including front and rear ear panels, waist cap features, elasticsand the like to provide better fit, containment and aestheticcharacteristics. Such additional features are well known in the art andare e.g., described in U.S. Pat. No. 3,860,003 and U.S. Pat. No.5,151,092.

In order to keep the diaper 10 in place about the wearer, at least aportion of the first waist region 30 may be attached by the fasteningmember 46 to at least a portion of the second waist region 32 to formleg opening(s) and an article waist. When fastened, the fastening systemcarries a tensile load around the article waist. The fastening systemmay allow an article user to hold one element of the fastening system,such as the fastening member 46, and connect the first waist region 30to the second waist region 32 in at least two places. This may beachieved through manipulation of bond strengths between the fasteningdevice elements.

According to certain embodiments, the diaper 10 may be provided with are-closable fastening system or may alternatively provided in the formof a pant-type diaper. When the absorbent article is a diaper, it maycomprise a re-closable fastening system joined to the chassis forsecuring the diaper to a wearer. When the absorbent article is apant-type diaper, the article may comprise at least two side panelsjoined to the chassis and to each other to form a pant. The fasteningsystem and any component thereof may include any material suitable forsuch a use, including but not limited to plastics, films, foams,nonwoven webs, woven webs, paper, laminates, fiber reinforced plasticsand the like, or combinations thereof. In certain embodiments, thematerials making up the fastening device may be flexible. Theflexibility may allow the fastening system to conform to the shape ofthe body and thus, reduce the likelihood that the fastening system willirritate or injure the wearer's skin.

For unitary absorbent articles, the chassis 12 and absorbent core 14 mayform the main structure of the diaper 10 with other features added toform the composite diaper structure. While the top sheet 18, the backsheet 20, and the absorbent core 14 may be assembled in a variety ofwell-known configurations, certain diaper configurations are describedgenerally in U.S. Pat. No. 5,554,145 to Roe et al.; U.S. Pat. No.5,569,234 to Buell et al.; and U.S. Pat. No. 6,004,306 to Robles et al.on Dec. 21, 1999.

The top sheet 18 in FIG. 1 may be fully or partially elasticized or maybe foreshortened to provide a void space between the top sheet 18 andthe absorbent core 14. Exemplary structures including elasticized orforeshortened top sheets are described in more detail in U.S. Pat. No.5,037,416 to Allen et al.; and U.S. Pat. No. 5,269,775 to Freeland etal.

The back sheet 20 may be joined with the top sheet 18. The back sheet 20may prevent the exudates absorbed by the absorbent core 14 and containedwithin the diaper 10 from soiling other external articles that maycontact the diaper 10, such as bed sheets and undergarments. In certainembodiments, the back sheet 20 may be substantially impervious toliquids (e.g., urine) and comprise a laminate of a nonwoven and a thinplastic film such as a thermoplastic film having a thickness of about0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils). Suitable back sheetfilms include those manufactured by Tredegar Industries Inc. (TerreHaute, Ind.) and sold under the trade names X15306, X10962, and X10964.Other suitable back sheet materials may include breathable materialsthat permit vapors to escape from the diaper 10 while still preventingexudates from passing through the back sheet 10. Exemplary breathablematerials may include materials such as woven webs, nonwoven webs,composite materials such as film-coated nonwoven webs, and microporousfilms such as manufactured by Mitsui Toatsu Co. (Japan) under thedesignation ESPOIR NO and by EXXON Chemical Co. (Bay City, Tex.) underthe designation EXXAIRE. Suitable breathable composite materialscomprising polymer blends are available from Clopay Corporation(Cincinnati, Ohio) under the name HYTREL blend P18-3097. Such breathablecomposite materials are described in PCT Application No. WO 95/16746,published Jun. 22, 1995 in the name of E.I. DuPont. Other breathableback sheets including nonwoven webs and apertured formed films aredescribed in U.S. Pat. No. 5,571,096 to Dobrin et al.

FIG. 2 shows a cross section of FIG. 1 taken along the sectional line2-2 of FIG. 1. Starting from the wearer facing side, the diaper 10 maycomprise the top sheet 18, the components of the absorbent core 14, andthe back sheet 20. According to a certain embodiment, diaper 10 may alsocomprise an acquisition system 50 disposed between the liquid permeabletop sheet 18 and a wearer facing side of the absorbent core 14. Theacquisition system 50 may be in direct contact with the absorbent core.The acquisition system 50 may comprise a single layer or multiplelayers, such as an upper acquisition layer 52 facing the towards thewearer's skin and a lower acquisition 54 layer facing the garment of thewearer. According to a certain embodiment, the acquisition system 50 mayfunction to receive a surge of liquid, such as a gush of urine, andquickly absorb the liquid and distribute it across the absorbent core 14so that the absorbent core absorbs the liquid before the liquid flowsbeyond the absorbent layer 14 and out of the diaper 10. In other words,the acquisition system 50 may serve as a temporary reservoir for liquiduntil the absorbent core 14 can absorb the liquid.

In a certain embodiment, the acquisition system 50 may comprisechemically cross-linked cellulosic fibers. Such cross-linked cellulosicfibers may have desirable absorbency properties. Exemplary chemicallycross-linked cellulosic fibers are disclosed in U.S. Pat. No. 5,137,537which is incorporated herein by reference. In certain embodiments, thechemically cross-linked cellulosic fibers have between about 0.5 mole %and about 10.0 mole % of a C₂ to C₉ polycarboxylic cross-linking agentor between about 1.5 mole % and about 6.0 mole % of a C₂ to C₉polycarboxylic cross-linking agent. Citric acid is an exemplarycross-linking agent. In other embodiments, polyacrylic acids may beused. Further, according to certain embodiments, the cross-linkedcellulosic fibers have a water retention value of about 25 to about 60,or about 28 to about 50, or about 30 to about 45. A method fordetermining water retention value is disclosed in U.S. Pat. No.5,137,537. According to certain embodiments, the cross-linked cellulosicfibers may be crimped, twisted, or curled, or a combination thereofincluding crimped, twisted, and curled.

In a certain embodiment, one or both of the upper and lower acquisitionlayers 52 and 54 may comprise a non-woven, which may be hydrophilic.Further, according to a certain embodiment, one or both of the upper andlower acquisition layers 52 and 54 may comprise the chemicallycross-linked cellulosic fibers, which may or may not form part of anonwoven material. According to an exemplary embodiment, the upperacquisition layer 52 may comprise a nonwoven, without the cross-linkedcellulosic fibers, and the lower acquisition layer 54 may comprise thechemically cross-linked cellulosic fibers. Further, according to anembodiment, the lower acquisition layer 54 may comprise the chemicallycross-linked cellulosic fibers mixed with other fibers such as naturalor synthetic polymeric fibers. According to exemplary embodiments, suchother natural or synthetic polymeric fibers may include high surfacearea fibers, thermoplastic binding fibers, polyethylene fibers,polypropylene fibers, PET fibers, rayon fibers, lyocell fibers, andmixtures thereof. According to a one embodiment, the lower acquisitionlayer 54 has a total dry weight, the cross-linked cellulosic fibers arepresent on a dry weight basis in the first acquisition layer in anamount from about 30% to about 95% by weight of the lower acquisitionlayer 54, and the other natural or synthetic polymeric fibers arepresent on a dry weight basis in the lower acquisition layer 54 in anamount from about 70% to about 5% by weight of the lower acquisitionlayer 54. According to another embodiment, the cross-linked cellulosicfibers are present on a dry weight basis in the first acquisition layerin an amount from about 80% to about 90% by weight of the loweracquisition layer 54, and the other natural or synthetic polymericfibers are present on a dry weight basis in the lower acquisition layer54 in an amount from about 20% to about 10% by weight of the loweracquisition layer 54.

According to a certain embodiment, the lower acquisition layer 54desirably has a high fluid uptake capability. Fluid uptake is measuredin grams of absorbed fluid per gram of absorbent material and isexpressed by the value of “maximum uptake.” A high fluid uptakecorresponds therefore to a high capacity of the material and isbeneficial, because it ensures the complete acquisition of fluids to beabsorbed by an acquisition material. According to exemplary embodiments,the lower acquisition layer 54 has a maximum uptake of about 10 g/g.

A relevant attribute of the lower acquisition layer 54 is its MediumDesorption Pressure (MDP) which is related to acquisition speed. The MDPis a measure of the capillary pressure that is required to dewater thelower acquisition layer 54 to about 50% of its capacity at 0 cmcapillary suction height as derived from the Capillary Sorption test.Generally, a relatively lower MDP may be useful. The lower MDP may allowthe lower acquisition layer 54 to more efficiently drain the acquisitionmaterial and utilize more of its capillary suction to distribute liquidto the absorbent core 14. Without wishing to be bound by theory, a givendistribution material may have a definable capillary suction. Theability of the lower acquisition layer 54 to move liquid vertically viacapillary forces will be directly impacted by the opposing capillaryforces associated desorption. Minimizing these capillary forces maypositively impact the performance of the lower acquisition layer 54.However, in a certain embodiment the lower acquisition layer 54 may alsohave adequate capillary absorption suction in order to drain the layersabove (upper acquisition layer 52 and top sheet 18, in particular) andto temporarily hold liquid until the liquid can be partitioned away bythe absorbent core components. Therefore, in a certain embodiment, thelower acquisition layer 54 may have a minimum MDP which shouldcorrespond to a height of greater than 5 cm. Further, according toexemplary embodiments, the lower acquisition layer 54 has an MDP valueof less than about 20.5 cm H₂O, or less than about 19 cm H₂O, or lessthan about 18 cm H₂O to provide for fast acquisition.

The methods for determining MDP and maximum uptake are disclosed in U.S.Patent Application Publication No. 2007/0118087 A1 (Flohr et al.), thedisclosure of which is incorporated herein by reference.

For example, according to one embodiment, the lower acquisition layer 54may comprise 7 about 0% by weight of chemically cross-linked cellulosefibers, about 10% by weight polyester (PET), and about 20% by weightuntreated pulp fibers. According to a second embodiment, the loweracquisition layer 54 may comprise about 70% by weight chemicallycross-linked cellulose fibers, about 20% by weight lyocell fibers, andabout 10% by weight PET fibers. According to a third embodiment, thelower acquisition layer 54 may comprise about 68% by weight chemicallycross-linked cellulose fibers, about 16% by weight untreated pulpfibers, and about 16% by weight PET fibers.

Suitable non-woven materials for the upper and lower acquisition layers52 and 54 include, but are not limited to SMS material, comprising aspunbonded, a melt-blown and a further spunbonded layer. In certainembodiments, permanently hydrophilic non-wovens, and in particular,nonwovens with durably hydrophilic coatings are desirable. Anothersuitable embodiment comprises a SMMS-structure. In certain embodiments,the non-wovens are porous.

In certain embodiments, suitable non-woven materials may include, butare not limited to, synthetic fibers, such as PE, PET, and PP. Aspolymers used for nonwoven production may be inherently hydrophobic,they may be coated with hydrophilic coatings. One way to producenonwovens with durably hydrophilic coatings, is via applying ahydrophilic monomer and a radical polymerization initiator onto thenonwoven, and conducting a polymerization activated via UV lightresulting in monomer chemically bound to the surface of the nonwoven asdescribed in U.S. Patent Application Publication No. 2004/0097895 A1(Busam et al.). Another way to produce nonwovens with durablyhydrophilic coatings is to coat the nonwoven with hydrophilicnanoparticles as described in U.S. Pat. No. 7,112,621 to Rohrbaugh etal. and PCT Application Publication WO 02/064877.

Typically, nanoparticles have a largest dimension of below 750 nm.Nanoparticles with sizes ranging form 2 to 750 nm may be economicallyproduced. An advantage of nanoparticles is that many of them can beeasily dispersed in water solution to enable coating application ontothe nonwoven, they typically form transparent coatings, and the coatingsapplied from water solutions are typically sufficiently durable toexposure to water. Nanoparticles can be organic or inorganic, syntheticor natural. Inorganic nanoparticles generally exist as oxides,silicates, carbonates. Typical examples of suitable nanoparticles arelayered clay minerals (e.g., LAPONITE™ from Southern Clay Products, Inc.(USA), and Boehmite alumina (e.g., Disperal P2™ from North AmericanSasol. Inc.). According to a certain embodiment, a suitable nanoparticlecoated non-woven is that disclosed in U.S. Patent ApplicationPublication No. 2004/0158212 (Ponomarenko et al.).

Further useful non-wovens are described in U.S. Pat. No. 6,645,569 toCramer et al., U.S. Pat. No. 6,863,933 to Cramer et al., U.S. Patent No.7,112,621 to Rohrbaugh et al., U.S. Patent Application Publication No.2003/0148684 (Cramer et al.), and U.S. Patent Application PublicationNo. 2005/0008839 (Cramer et al.)

In some cases, the nonwoven surface can be pre-treated with high energytreatment (corona, plasma) prior to application of nanoparticlecoatings. High energy pre-treatment typically temporarily increases thesurface energy of a low surface energy surface (such as PP) and thusenables better wetting of a nonwoven by the nanoparticle dispersion inwater.

Notably, permanently hydrophilic non-wovens are also useful in otherparts of an absorbent article. For example, top sheets and absorbentcore layers comprising permanently hydrophilic non-wovens as describedabove have been found to work well.

According to a certain embodiment, the upper acquisition layer 52 maycomprise a material that provides good recovery when external pressureis applied and removed. Further, according to a certain embodiment, theupper acquisition layer 52 may comprise a blend of different fibersselected, for example from the types of polymeric fibers describedabove. In some embodiments, at least a portion of the fibers may exhibita spiral-crimp which has a helical shape. In some embodiments, the upperacquisition layer 52 may comprise fibers having different degrees ortypes of crimping, or both. For example, one embodiment may include amixture of fibers having about 8 to about 12 crimps per inch (cpi) orabout 9 to about 10 cpi, and other fibers having about 4 to about 8 cpior about 5 to about 7 cpi. Different types of crimps include, but arenot limited to, a 2D crimp or “flat crimp” and a 3D or spiral-crimp.According to a certain embodiment, the fibers may include bi-componentfibers, which are individual fibers each comprising different materials,usually a first and a second polymeric material. It is believed that theuse of side-by-side bi-component fibers is beneficial for imparting aspiral-crimp to the fibers.

The upper acquisition layer 52 may be stabilized by a latex binder, forexample a styrene-butadiene latex binder (SB latex), in a certainembodiment. Processes for obtaining such lattices are known, forexample, from EP 149 880 (Kwok) and U.S. Patent Application PublicationNo. 2003/0105190 (Diehl et al.). According to a certain embodiment, SBlattices may be obtained using more than about 10 weight % of a mono-,or bi-carboxylic acid, and will herein be referred to as having acarboxylation level of more than about 10%. Further, according to acertain embodiment, SB lattices may have a carboxylation level fromabout 10% to about 25%, for example about 10% to about 20%. In certainembodiments, the binder may be present in the upper acquisition layer 52in excess of about 12%, about 14% or about 16% by weight. For certainembodiments, SB latex is available under the trade name GENFLO™ 3160(OMNOVA Solutions Inc.; Akron, Ohio).

The absorbent core 14 in FIGS. 1-10 generally is disposed between thetop sheet 18 and the back sheet 20 and comprises two layers, a firstabsorbent layer 60 and a second absorbent layer 62. As best shown inFIG. 3, the first absorbent layer 60 of the absorbent core 14 comprisesa substrate 64, an absorbent particulate polymer material 66 on thesubstrate 64, and a thermoplastic composition 68 on the absorbentparticulate polymer material 66 and at least portions of the firstsubstrate 64 as an adhesive for covering and immobilizing the absorbentparticulate polymer material 66 on the first substrate 64. According toanother embodiment illustrated in FIG. 4, the first absorbent layer 60of the absorbent core 14 may also include a cover layer 70 on thethermoplastic composition 68. The absorbent core 14 may also includeanother layer 69 of thermoplastic composition on the first substrate 64for anchoring the absorbent particulate polymer material 66 to the firstsubstrate 64.

Likewise, as best illustrated in FIG. 2, the second absorbent layer 62of the absorbent core 14 may also include a substrate 72, athermoplastic composition 73 on the substrate, an absorbent particulatepolymer material 74 adhered to the second substrate 72 with thethermoplastic composition, and a thermoplastic composition 68 on theabsorbent particulate polymer material 74 and at least a portion of thesecond substrate 72 or first layer of thermoplastic composition forimmobilizing the absorbent particulate polymer material 74 on the secondsubstrate 72. Although not illustrated, the second absorbent layer 62may also include a cover layer such as the cover layer 70 illustrated inFIG. 4.

The substrate 64 of the first absorbent layer 60 may be referred to as adusting layer and has a first surface 78 which faces the back sheet 20of the diaper 10 and a second surface 80 which faces the absorbentparticulate polymer material 66. Likewise, the substrate 72 of thesecond absorbent layer 62 may be referred to as a core cover and has afirst surface 82 facing the top sheet 18 of the diaper 10 and a secondsurface 84 facing the absorbent particulate polymer material 74. Thefirst and second substrates 64 and 72 may be adhered to one another withadhesive about the periphery to form an envelope about the absorbentparticulate polymer materials 66 and 74 to hold the absorbentparticulate polymer material 66 and 74 within the absorbent core 14.

According to a certain embodiment, the substrates 64 and 72 of the firstand second absorbent layers 60 and 62 may be a non-woven material, suchas those nonwoven materials described above. In certain embodiments, thenon-wovens are porous and in one embodiment has a pore size of about 32microns.

As illustrated in FIGS. 1-8, the absorbent particulate polymer material66 and 74 may be deposited on the respective substrates 64 and 72 of thefirst and second absorbent layers 60 and 62 in small and large clusters90 and 91 of particles to form a grid pattern 92 comprising land areas94 and junction areas 96 between the land areas 94. The junction areas96 in the grid pattern 92 contain little or no absorbent particulatepolymer material 66 and 74. The land areas 94 and junction areas 96 canhave a variety of shapes including, but not limited to, circular, oval,square, rectangular, triangular, and the like.

The small clusters 90 of absorbent particulate polymer material 66 and74 are thinner than the large clusters 91 of absorbent particulatepolymer material 66 and 74 and impart a lower basis weight of absorbentparticulate polymer material 66 and 74 to the area of the absorbent core14 in which the small clusters 90 are located. Likewise, the largeclusters 91 of absorbent particulate polymer material 66 and 74 arethicker than the small clusters 90 of absorbent particulate polymermaterial 66 and 74 and impart a higher basis weight of absorbentparticulate polymer material 66 and 74 to the area of the absorbent core14 in which the large clusters 91 are located. This creates a variedprofile of absorbent particulate polymer material across the absorbentcore 14. At least one cavity can be created in the absorbent core by acombination of machine direction profiling and cross-machine directionprofiling, so as to create at least one region having relatively littleor no absorbent particulate polymer material (e.g., a low basis weightregion) bounded by a region of relatively more absorbent particulatepolymer material (i.e., a high basis weight region).

As shown in FIG. 8, the absorbent core 14 has a longitudinal axis 100extending from a rear end 102 to a front end 104 and a transverse axis106 perpendicular to the longitudinal axis 100 extending from a firstedge 108 to a second edge 110. The grid pattern 92 of absorbentparticulate polymer material clusters 90 and 91 is arranged on thesubstrates 64 and 72 of the respective absorbent layers 60 and 62 suchthat the grid pattern 92 formed by the arrangement of land areas 94 andjunction areas 96 forms a pattern angle 112. While the pattern angle 112may be such that the grid pattern 92 is parallel with the first andsecond edges 108 and 110 of the absorbent core 14, the pattern angle 112may be greater than 0, or 15 to 30 degrees, or from about 5 to about 85degrees, or from about 10 to about 60 degrees, or from about 15 to about30 degrees from the longitudinal axis 100 of the absorbent core 14.

As best seen in FIGS. 7 and 8, the first and second layers 60 and 62 maybe combined to form the absorbent core 14. The absorbent core 14 has anabsorbent particulate polymer material area 114 bounded by a patternlength 116 and a pattern width 118. The extent and shape of theabsorbent particulate polymer material area 114 may vary depending onthe desired application of the absorbent core 14 and the particularabsorbent article in which it may be incorporated. In a certainembodiment, however, the absorbent particulate polymer material area 114may extend substantially entirely across the absorbent core 14, such asis illustrated in FIG. 8.

The size of the land areas 94 in the grid patterns 92 may vary.According to certain embodiments, the width of the land areas 94 in thegrid patterns 92 ranges from about 8 mm to about 12 mm. In a certainembodiment, the width of the land areas 94 is about 10 mm. The junctionareas 96, on the other hand, in certain embodiments, have a width orlarger span of less than about 5 mm, less than about 3 mm, less thanabout 2 mm, less than about 1.5 mm, less than about 1 mm, or less thanabout 0.5 mm.

The first and second absorbent layers 60 and 62 may be combined togetherto form the absorbent core 14 such that the grid patterns 92 of therespective first and second absorbent layers 62 and 64 are offset fromone another along the length and/or width of the absorbent core 14. Therespective grid patterns 92 may be offset such that the absorbentparticulate polymer material 66 and 74 is substantially continuouslydistributed across the absorbent particulate polymer area 114. In acertain embodiment, absorbent particulate polymer material 66 and 74 issubstantially continuously distributed across the absorbent particulatepolymer material area 114 despite the individual grid patterns 92comprising absorbent particulate polymer material 66 and 74discontinuously distributed across the first and second substrates 64and 72 in clusters 90 and 91. In a certain embodiment, the grid patternsmay be offset such that the land areas 94 of the first absorbent layer60 face the junction areas 96 of the second absorbent layer 62 and theland areas of the second absorbent layer 62 face the junction areas 96of the first absorbent layer 60. When the land areas 94 and junctionareas 96 are appropriately sized and arranged, the resulting combinationof absorbent particulate polymer material 66 and 74 is a substantiallycontinuous layer of absorbent particular polymer material across theabsorbent particulate polymer material area 114 of the absorbent core14. In a certain embodiment, respective grid patterns 92 of the firstand second absorbent layer 60 and 62 may be substantially the same.

In a certain embodiment as illustrated in FIGS. 1-8, the amount ofabsorbent particulate polymer material 66 and 74 may vary along thewidth 118 of the grid pattern 92 substantially perpendicularly to thelongitudinal axis 36 of disposable absorbent diaper 10. In a certainembodiment, the grid pattern may be divided into absorbent zones 120,121 and 122, or another number of zones, in which the amount ofabsorbent particulate polymer material 66 and 74 per unit area of theabsorbent core 14 varies from zone to zone. The amount of absorbentparticulate polymer material 66 and 74 may, in a certain embodiment,gradually transition from one of the plurality of absorbent zones 120,121, and 122 to another. This gradual transition in amount of absorbentparticulate polymer material 66 and 74 may reduce the possibility ofcracks forming in the absorbent core 14.

In the embodiment illustrated in FIGS. 1-8 the first and second sideabsorbent zones 120 and 122 are spaced from one another and extendsubstantially parallel to the longitudinal axis 36 of the diaper 10 andthe central absorbent zone 121 extends substantially along thelongitudinal axis and between the first and second side absorbent zones120 and 122. The absorbent particulate polymer material 66 and 74present in the first and second side absorbent zones 120 and 122 of theabsorbent core 14 has a basis weight greater than the basis weight ofthe absorbent particulate polymer material 66 and 74 present in thecentral absorbent zone 121 of the absorbent core 14.

In alternative embodiments, the absorbent particulate polymer material66 and 74 in the central absorbent zone 121 of the absorbent core 14 hasa higher basis weight than in the first and second side absorbent zones120 and 122 of the absorbent core 14. When the absorbent core 14according to this embodiment is subjected to a flush of liquid directedat the central absorbent zone 121, liquid that flows over and past thecentral absorbent zone 121 contacts the side absorbent zones 120 and122. The first and second side absorbent zones 120 and 122 have moreabsorbent particulate polymer material and have greater capacity toabsorb such liquid and deter flow of the liquid beyond the sideabsorbent zones 120 and 122 to prevent leakage.

Although the embodiment illustrated in FIGS. 1-8 has only threeabsorbent zones 120, 121, and 122, the absorbent diaper 10 may includeany number of absorbent zones having varying basis weights of absorbentparticulate polymer. Furthermore, in other embodiments, the absorbentparticulate polymer material 66 and 74 may be varied in differentpatterns such as by placing more absorbent particulate polymer materialin the central absorbent zone 121 than in the side absorbent zone 120and 122 or alternating areas of greater and lesser amounts of absorbentparticulate polymer material per unit area of the absorbent core.

Another embodiment of an absorbent core 14′ is illustrated in FIG. 9 andthe basis weight of the absorbent particulate polymer material 66 and 74varies across the absorbent core 14′ in a direction substantiallyparallel to the longitudinal axis 36. This absorbent core 14′ comprisesfirst and second end absorbent zones 123 and 124, spaced form oneanother and extending substantially perpendicular to the longitudinalaxis of the absorbent core, and a central absorbent zone 125, extendingsubstantially along the longitudinal axis 36 and between the first andsecond end absorbent zones 123 and 124. The basis weight of theabsorbent particulate polymer material in the absorbent end zones 123and 124 of the absorbent core 14′ is greater than in the centralabsorbent zone 125 of the absorbent core 14′. When the absorbent core14′ illustrated in FIG. 9 is subjected to a flush of liquid directed atthe central absorbent zone 125, liquid that flows past the centralabsorbent zone 125 encounters end absorbent zones 123 and 124 which havegreater capacity to absorb and hold such liquid.

Although the absorbent core 14′ illustrated in FIG. 9 has only threeabsorbent zones 123, 124, and 125, the absorbent core 14′ may includeany number of absorbent zones arranged in a variety of differentpatterns of varying absorbent particulate polymer material basisweights. In other embodiments, the basis weight of the absorbentparticulate polymer material 66 and 74 in the central absorbent zone 125may be greater than in the end absorbent zones 123 and 124 or theabsorbent core 14′ may include a multitude of alternating absorbentzones of varying absorbent particulate polymer material basis weights.

Another embodiment of an absorbent core 14″ is illustrated in FIG. 10and comprises first and second side absorbent zones 120′ and 122′ spacedfrom one another and extending substantially parallel to thelongitudinal axis 36, first and second end absorption zones 123′ and124′ spaced from one another and extending substantially perpendicularlyto the longitudinal axis 36, and a central portion 121′ and 125′extending substantially along the longitudinal axis 36 and between thefirst and second side absorbent zones 120′ and 122′ and between thefirst and second end absorbent zones 123′ and 124′. The basis weight ofthe absorbent particulate polymer material 66 and 74 in the first andsecond side portions 120′ and 122′ of the absorbent core 14″ is greaterthan the basis weight of the absorbent particulate polymer material 66and 74 in the central portion 121′ and 125′ of the absorbent core 14″and the basis weight of the absorbent particulate polymer material 66and 74 in the first and second end portions 123′ and 124′ of theabsorbent core 14″ is greater than the basis weight of the absorbentparticulate polymer material 66 and 74 in the central portion 121′ and125′ of the absorbent core 14″. When the absorbent core 14″ illustratedin FIG. 10 is subjected to a rush of liquid directed at the centralabsorbent zone 121′ and 125′, liquid that flows past the centralabsorbent zone 121′ and 125′ encounters and may be absorbed by the sideabsorbent zones 120′ and 122′ and the end absorbent zones 123′ and 124′which all have greater absorbent particulate polymer material basisweights. As with the other embodiments described hereinabove, it shouldbe understood that the absorbent particulate polymer material 66 and 74may be arranged in a variety of different patterns of varying absorbentparticulate polymer material basis weights. In one such embodiment, thecentral absorbent zone 121′ and 125′ may have a higher absorbentparticulate polymer material basis weight than the side absorbent zones120′ and 122′ and the end absorbent zones 123′ and 124′.

A certain embodiment of an absorbent core 214 is illustrated in FIGS.11-12. Absorbent core 214 may be constructed like absorbent cores 14,14′, or 14″ described herein. The absorbent core 214 comprises at leastone cavity 215, which is sized and positioned to receive fecal matter,for example to contain and direct the fecal matter away from the skin ofa person wearing a disposable absorbent article which comprises theabsorbent core 214. In certain embodiments, the void volume of thecavity (or total volume of multiple cavities) may be from 2 ml to about20 ml when the absorbent core 214 is in a dry state. When the absorbentcore 214 becomes wet, expansion of the absorbent particulate polymermaterial 66 and 74 swells, causing the cavity volume to increase. Forexample, the void volume of the cavity may be from about 25 ml to 35 ml(in use, when fluid is present), e.g., about 30 ml. In one embodiment,the cavity volume may be from about 50 to about 70 ml when the absorbentcore is in a saturated state.

The cavity may be defined at least about its perimeter by the absorbentparticulate polymer material 66 and 74 (with associated first and secondsubstrates 64 and 72 and thermoplastic material 68 and 76). For example,the cavity may be formed by CD and MD profiling of the core, creating anarea with a lower basis weight absorbent particulate polymer material,or no absorbent particulate polymer material, as compared to surroundingareas of the absorbent core. Generally, the greater the basis weightdifference between the regions, the greater the depth of the cavity. Thevolume of the cavity may increase upon swelling of the absorbentparticulate polymer material, i.e., after at least one gush of liquidoccurs and is taken up by the absorbent particulate polymer material.

In a particular embodiment, the region defining the cavity may besubstantially free of absorbent particulate polymer material 66 and 74.In one embodiment, the absorbent particulate polymer material that wouldhave been located in the region of the cavity may be redistributed inthe absorbent core in the region about the walls or perimeter of thecavity. In this way, the total capacity of the absorbent core issubstantially maintained as compared to an absorbent core without such acavity. One embodiment of such an absorbent core is illustrated in FIG.28, as detailed below.

In one embodiment, the first channel of the cavity is located in theabsorbent core along the central longitudinal axis of the diaper or pantat a position which is positioned at the so-called “poo point.” That is,when the diaper or pant is worn by a wearer, the cavity will be inalignment with a predetermined region about the anus of the wearer. Inone embodiment, the cavity is located about 10 mm from the anusposition, which may work to direct the bowel movement into the cavity.

In a certain embodiment, the cavity 215 may include a first channel 219elongated in a direction substantially parallel to and located about thecentral longitudinal axis 100, and (ii) a second channel 217 elongatedin a direction substantially perpendicular to the central longitudinalaxis 100. In one embodiment, the first and second channels of the cavitytogether may form a T-shape, as illustrated in FIG. 11. In otherembodiments, the first and second channels of the cavity together mayform a cross shape, or a Y-shape. The dimensions of the first channelgenerally should create a stable valley between the buttocks, yetprovide a channel for fecal matter; if too wide then the first channelloses stability and if too narrow then it does not adequatelyaccommodate the bowel movement. In various embodiments, the firstchannel 219 of the cavity 215 may have a width from about 10 mm to about40 mm and a length from about 10 mm to about 130 mm. In one example, thefirst channel 219 of the cavity 215 may have a width of about 20 mm andmay have a length of about 70 mm. The second channel generally should bedimensioned to provide distribution of the bowel movement in the crossdirection once it has been directed to the back of the diaper. In othervarious embodiments, the second channel 217 of the cavity 215 may have awidth from about 10 mm to about 40 mm and a length from about 10 mm toabout 100 mm. In another example, the second channel of the cavity mayhave a width of about 30 mm and a length of about 50 mm. In thisT-shaped cavity embodiment, channel length refers to dimensions in themachine direction, and channel width refers to dimensions in thecross-machine direction.

The one or more cavities in the absorbent core may have a variety ofdifferent geometric shapes. Combinations of different geometric shapesmay be used together. The shapes may be connected or may be discretefrom one another. The cavities generally are sized and located in theabsorbent core in a position to facilitate reception and storage of bodyexudates, such as fecal matter. The shapes generally may straddle thelongitudinal axis. FIG. 24 illustrates various examples of possibleshapes and designs of cavities 215 in the absorbent core 214, includingT-shaped, triangular, diamond, Y-shaped, combination of semi-circle andrectangle, oval, trapezoidal, combination of rectangle and triangle,array of discrete rectangles, array of rectangles connected withperpendicular bar, circular elliptical, V-shaped, X-shaped, triangular,array of circles connected with bar, interrupted triangular, U-shaped,and star-shaped.

In addition to the basis weight variation, e.g., the CD and MDprofiling, to define the at least one cavity of the absorbent core, theabsorbent particulate polymer material present in the remaining part ofthe absorbent core (other than the at least one cavity) may have a basisweight that varies across other areas of the absorbent core in adirection substantially perpendicular to the central longitudinal axis,in a direction substantially parallel to the central longitudinal axis,or in both directions. Generally, the absorbent particulate polymermaterial is redistributed away from the cavity area, so that the liquidloading capacity is substantially maintained (versus a conventional flatabsorbent core). In one embodiment, illustrated with reference to FIG.11, the absorbent core 214 includes back end and front end absorbentzones 220 a and 220 b, respectively. The cavity 215 is defined in andbounded by central absorbent zones 226 and 224, and rear transitionalabsorbent zone 225 disposed therebetween. The central absorbent zone 226and front end absorbent zone 220 b front end have a front transitionalzone 222 disposed therebetween.

In an embodiment, the basis weight of absorbent particulate polymermaterial in back end and front end absorbent zones 220 a and 220 b isfrom about 200 g/cm² to about 300 g/cm², for example between about 220g/cm² and 250 g/cm², such as about 233 g/cm². In an embodiment, thebasis weight of absorbent particulate polymer material in centralabsorbent zone 224 is from about 450 g/cm² to about 650 g/cm², forexample, between about 530 g/cm² and 600 g/cm², such as about 568 g/cm².In an embodiment, the basis weight of absorbent particulate polymermaterial in central absorbent zones 226 is from about 200 g/cm² to about400 g/cm², for example, between about 250 g/cm² and 350 g/cm², such asabout 284 g/cm². In an embodiment, the rear transitional absorbent zone225 has a basis weight of absorbent particulate polymer material betweenabout 300 g/cm² and 400 g/cm², such as about 333 g/cm². In anembodiment, the front transitional absorbent zone 222 has a basis weightof absorbent particulate polymer material between about 200 g/cm² and300 g/cm², for example between about 240 g/cm² and 280 g/cm². Transitionzones are optional, and each transition zone may comprise furthergradation within the transition zone.

The absorbent core 214 may comprise a core cover 72 and a dusting layer64 adhered to one another about the periphery of the absorbent core 214to form an envelope about the absorbent particulate polymer materials66/74 to hold the absorbent particulate polymer material within theabsorbent core 214.

The cavity may be formed with various constructions. For example, FIG.25A illustrates one embodiment in which some of the absorbentparticulate polymer materials 66/74 is present in the cavity 215, but ata lower basis weight relative to the surrounding region of the absorbentcore 214. In another embodiment, as illustrated in FIG. 25B,substantially none of the absorbent particulate polymer materials 66/74is present in the cavity 215.

In a particular embodiment, the core cover 72 and the dusting layer 64may be adhered to one another about an area defining the bottom of theat least one cavity 215, as illustrated in FIG. 25C. In this embodiment,there is no absorbent particulate polymer material in the bottom of thecavity; however, the sidewalls of the cavity are still defined by theabsorbent particulate polymer material. This embodiment may aid cavityshape/volume retention when the absorbent particulate polymer materialsswells and takes additional volume, as it would be undesirable for theabsorbent particulate polymer materials to swell and thereby reduce thecavity volume available for receiving and holding a bowel movement. In acertain sub-embodiment, most or all of layers of the absorbent articleconstruction about the cavity are connected to the dusting layer, inorder to sustain the cavity. These layers can be glued or bonded byapplication of heat and/or pressure.

In one embodiment, the disposable absorbent article 10 may furtherinclude an acquisition system 50 located between the absorbent core 214and the top sheet 18. In one embodiment, the acquisition system 50 mayinclude an upper acquisition layer 52, which faces the top sheet 18, anda lower acquisition layer 54, which faces the absorbent core 214. Theupper acquisition layer 52 may or may not cover the at least one cavity215. The lower acquisition layer 54 may or may not cover the at leastone cavity 215. In another embodiment, the lower acquisition layer maybe omitted. Various constructions of absorbent core and acquisitionlayers are possible; examples are illustrated in FIGS. 26-28.

In one embodiment, the at least one cavity 215 may further be definedabout its perimeter by interior edges of an aperture 216 in theacquisition system 50 and absorbent core 214, as illustrated in FIG.26A. In an alternative embodiment, the absorbent core is substantiallyplanar and the cavity is defined substantially by interior edges of anaperture 216 in the acquisition system 50, as illustrated in FIGS.26B-C. In this embodiment, the void volume achieved is a function of thethickness of the acquisition system. In one embodiment, the aperture 216in the acquisition system 50, which defines the shape of the cavity, maybe made by a stamping process, adapted from stamping equipment andprocesses known in the art. The borders of the acquisition layer may besealed.

FIGS. 27A-E illustrate some of the possible configurations of theacquisition system 50 and absorbent core 214. In FIG. 27A, the cavity215 is not covered at all by the acquisition system 50, which is offsettoward the front end of the absorbent core (e.g., toward the pee point).In FIG. 27B, the cavity 215 is partially covered by the acquisitionsystem 50. In FIG. 27C, the cavity 215 is completely covered by theacquisition system 50. In FIG. 27D, a majority of the (smaller)acquisition system 50 is positioned over the cavity 215. In FIG. 27E,the acquisition system 50 is shaped to surround part of, but not cover,the cavity 215.

The upper and lower acquisition layers 52 and 54 may, but need not,cover identical areas of the absorbent core 214. In various embodiments,the upper and lower acquisition layers 52 and 54 may have differentsizes and/or positions relative to the absorbent core. In FIG. 27F, theupper acquisition layer 52 covers part of the cavity 215, and the loweracquisition layer 54 covers none of the cavity. In FIG. 27G, the upperacquisition layer 52 covers part of the cavity 215, and the loweracquisition layer 54 is shaped to surround part of but not cover thecavity 215. In FIG. 27H, the upper acquisition layer 52 covers all ofthe cavity 215, and the lower acquisition layer 54 is shaped to surroundpart of but not cover the cavity 215. In FIG. 27I, the upper and loweracquisition layers 52 and 54 are approximately coextensive and includean aperture surrounding all of the cavity 215 in the absorbent core 214.In FIG. 27J, the upper acquisition layer 52 covers all of the cavity215, and the lower acquisition layer 54, which is smaller than the upperacquisition layer 52 and does not cover the cavity 215. In FIG. 27K, thecavity 215 is covered by a single (upper) acquisition layer 52.

In another alternative embodiment, an absorbent core is provided with acavity that is a through hole extending all the way through the corecover, absorbent particulate polymer materials, and dusting layer. Forinstance the cavity may be formed by a stamping process, and then theborders/edges of the cavity may be sealed, for example, by use of anadhesive and/or a heating or pressure process. In such an embodiment,the back sheet, and/or another layer, of the absorbent article may serveas the back/bottom of the cavity to contain the bowel movement.

The acquisition system may augment the caliper of the cavity of theabsorbent article. In one embodiment, shown in FIGS. 28A-B, theabsorbent core 214 includes a cavity 215, which is partially covered byan acquisition layer 52. The basis weight (and thickness) of theabsorbent particulate polymer material in the absorbent core 214 variesin the regions about the cavity 215. The basis weight in region 232 ishigher than the basis weight in region 234. Region 233 may provide asmooth gradient of basis weight between regions 232 and 234. Theacquisition layer 52 may supplement the caliper of region 234 toapproach, meet, or exceed the caliper of region 232.

In another embodiment, which is illustrated in FIGS. 13 and 14, anabsorbent core 214 is part of a disposable absorbent article 302 thatcomprises an elasticized top sheet 311, which includes an opening 314and that in use forms a void 355 for fecal matter encapsulation. Thisopening 314 is an area completely circumscribed by the top sheet 311,but where the top sheet material is not present, and which is largeenough to receive fecal material, for example, being at least 2 cm longor wide, or having a surface area of at least 2 cm². In a certainembodiment, the elasticized top sheet 314 generally is located adjacentthe cavity 215, such that at least a portion of the opening 314 may besubstantially aligned with the first channel 219 of the cavity 215 inthe absorbent core 214.

The top sheet 311 and the opening 314 each have a front region 321 and aback region 322. The diaper 302, illustrated in FIGS. 13-14, includes aback waist band with ears with fasteners 318 and a front waist band 359with receiving areas for the fasteners. In some configurations, thefasteners comprise hooks and/or adhesive and the receiving areas may beformed from loop-containing material. The diaper 302 further may includeelasticated bands along the longitudinal side edges of the diaper 302,so called leg cuffs 320. Leg cuffs may also be referred to as leg bands,side flaps, barrier cuffs, or elastic cuffs, as described in; U.S. Pat.No. 3,860,003; U.S. Pat. No. 4,808,178 and U.S. Pat. No. 4,909,803; U.S.Pat. No. 4,695,278 and U.S. Pat. No. 4,795,454.

The disposable absorbent article 302 may also include a sub-layer (whichmay be part of the absorbent core) disposed between the top sheet 311and the absorbent core 214, capable of accepting, and/or immobilizingbodily exudates, typically fecal material. For example as shown in FIG.14, the absorbent core 214 may comprise a specific sub-layer 324, whichcomprises means to immobilize fecal material, for example, a layer withvertically extending (z-direction) fibers, or an apertured web or film,as described herein. Suitable materials for use as the sub-layer mayinclude large cell open foams, macro-porous compression resistant nonwoven highlofts, large size particulate forms of open and closed cellfoams (macro and/or microporous), highloft non-wovens, polyolefin,polystyrene, polyurethane foams or particles, structures comprising amultiplicity of vertically oriented, which may be looped, strands offibers, and/or apertured formed films. (As used herein, the term“microporous” refers to materials that are capable of transportingfluids by capillary action, but having a mean pore size of more than 50microns. The term “macroporous” refers to materials having pores toolarge to effect capillary transport of fluid, generally having poresgreater than about 0.5 mm (mean) in diameter and more specifically,having pores greater than about 1.0 mm (mean) in diameter, but typicallyless than 10 mm or even less than 6 mm (mean).

The top sheet 311 with at least one opening 314 may be made as describedin U.S. Patent Application Publication No. 2007/0197992 A1 to Martynuset al., which is incorporated herein by reference. The top sheet mayfurther comprise, in one embodiment, a genital coversheet as describedin the same published application.

The exact shape of the opening 314 may vary, depending on the size ofthe top sheet 311 and/or the absorbent article 302. For example, in oneembodiment the opening is in the form of a slit opening withsubstantially parallel longitudinal side edges, which are connected inthe front and back by V-shaped or rounded V-shaped, as shown in FIG. 13,front and back edges, wherein both the front and back V-shaped edgescomprise two angled edges. In some embodiments, the back V-shaped edgesmay have a larger angle than the front V-shaped edges. The frontV-shaped edges may have an angle of 20° to 100° or, alternately, from45° to 65°, as shown in FIG. 14. The slit opening may optionally extendinto an additional cut-out area which is, for example, diamond shaped.In an embodiment, best illustrated in FIG. 14, the opening 314 comprisesa front end portion 336, which is curved, disposed between longitudinalside edges 316 of the opening.

The dimensions the opening 314 may also vary, depending on the size ofthe top sheet 311 and/or the absorbent article 302. In some embodiments,the top sheet 311 may have a slit opening having a longitudinaldimension (length) substantially parallel to the longitudinal axis ofthe top sheet 311 and of the diaper 302. In a stretched state, theopening 314 (or openings) of the top sheet may be configured such thatfrom 20% to 40% or from 20% to 30% of the length of the opening (ortotal length of the openings) extends from the transverse axis of thetop sheet toward the front edge of the top sheet, and the remainingpercentage extends towards the back edge of the top sheet. In someembodiments, the maximum length of the slit opening may be about 40% to90%, about 50% to 80%, or about 60% to 70% of the total length L of theabsorbent article. In one example, a size 4 diaper may have a maximumtop sheet length of between 45 cm and 55 cm or between 48 cm and 52 cm.In some embodiments, the length of the single slit opening, when thediaper is in stretched state, may be from 20 cm to 40 cm; from 25 cm to35 cm; or from 28 cm to 32 cm. In some embodiments, the average width ofthe opening, in stretched state, may be from 5% to 30% or 10% to 25% ofthe average width of the top sheet (including opening width). In oneexample, a size 4 diaper may have an average width of the opening offrom 15 mm to 60 mm or from 20 mm to 40 mm.

As shown in FIG. 13, the top sheet 311 may include a primary elasticatedarea 331 adjacent to or in close proximity with each longitudinal sideedge 316 of the opening 314 to form a pair of opposing, elasticatedareas. In some embodiments, the primary elasticated areas may extendfrom the side edges 316 of the opening 314 towards or completely to thefront and back edge of the top sheet 311. Thus, the primary elasticatedareas may be longer than the opening 314. The elasticated area may bepositioned over the full length of the top sheet, or at least the partof the top sheet which in use is intended to receive body exudates(e.g., the top sheet minus the parts thereof which form (part of) thewaist bands). An elasticated area in the top sheet may be formed from amultitude of thin strands of elastic material or, for example, from asingle band of elastic material. The absorbent article may also includesecondary elasticated areas in each crotch side portion (i.e., theportion of the top sheet between the longitudinal side edge of the topsheet 311 and the longitudinal side edge of the opening 314). Eachsecondary elasticized area may have an overall curvature, curving awayfrom the primary elasticated area of the same crotch side portion.

As shown in FIG. 13, the primary elasticated areas 331 may be positionedalong the longitudinal side edges 316 of the opening 314. The top sheet311 may also have secondary elasticated areas 332, or even tertiaryelasticated areas (not shown). The primary elasticated areas 331 haveeach a central region with a length L₂, the central regions beingsubstantially parallel to one another, whereby L₂ may be about 30% to70% of the total length L₁ of the primary elasticated areas 331. In anembodiment, L₂ is about 40% to 80% of the maximum length of the opening314. The primary elasticated areas 331 may have an X-shape, whereby thefront end portions 336 bend away from one another and the back endportions 338 bend away from one another. The primary elasticated areasmay also be parallel, such as described in EP Application PublicationEP-A-1201212.

The primary elasticated area may be shaped such that it has a centralportion that is substantially parallel to the central portion of theopposing primary elasticated area. In an embodiment, the central portionhas a length L₂ which may be 30% to 70% of the total length L₁ of acorresponding elasticated area, and may be about 40% to 80% of themaximum length of the opening. In some embodiments, the total length ofthe elasticated area may be about 70% to 90%, about 80% to 90%, or about85% of maximum length of the top sheet 311. The length of the primaryelasticated area may also depend on the size of the top sheet 311 and/orthe article 302. For example, for a size 4 diaper as described above theaverage length of the elasticated area in stretched state, may be atleast 35 cm, or from 35 cm to 45 cm. The width of the elasticated areason the top sheet may also vary, depending on the exact dimensions of thetop sheet 311 and/or the article 302. For example, for size 4 diapers asdescribed above, a primary elasticated area, in stretched state, may bean elastic band, or a multitude of elastic strands, that has an averagewidth of about 3 mm to 50 mm, about 3 mm to 40 mm, about 3 mm to 20 mm,or about 5 mm to 20 mm.

The front end portions of two opposing primary elasticated areas maybend away from one another (in the plane of the top sheet), so that thedistance between the end edges of the opposing front end portions of twoopposing elastic areas is larger than the distance between the centralportions of two opposing elastic areas, and equally, the distancebetween the end edges of the opposing back end portions of two opposingelastic areas is larger that the distance between the central portionsof two opposing elastic areas. For example, as shown in FIG. 14, theprimary elasticated areas 331 may be in the shape of an X, whereby eachfront end portion 336 of the elasticated area has an angle a with thelongitudinal line 335 parallel to the longitudinal axis of the top sheet311 and through that part of the elasticated area that is (directly)adjacent a longitudinal side edge 316 of the opening. In one embodiment,this angle a may be about 17° to 30° in stretched state. In oneembodiment, each back end portion 338 of the elasticated area also mayhave an angle which may be about 17° to 30° in stretched state.

In some embodiments, the front end portion of a primary elasticated areamay have an angle with a longitudinal line through the central portionof the elasticated area and parallel to the longitudinal axis of the topsheet, the angle may be between 10° and 40°, between 17° to 35°, orbetween 20° and 35°. In other embodiments, the back end portion of eachof the primary elasticated areas may have an angle with a longitudinalline through the central portion of the elasticated area and parallel tothe longitudinal axis of the top sheet. In some embodiments, the anglemay be between 10° and 40°, between 17° to 35°, or between 20° and 35°.When both front end portions and both back end portions have an angle asabove, the primary elasticated areas have, as is herein referred to, anX-shape, and a suitable X-shape is exemplified in FIGS. 13.

In some embodiments, the front end and/or the back end and/or thecentral portion of an elasticated area may be curved rather thanstraight. In such an embodiment, the angles above may be determined bythe angle of the tangent line through the center point of the front endand/or back end, with the line parallel to the longitudinal axis of thetop sheet and tangent to the center point of the central portion of theelasticated area.

The elasticated areas herein may be formed by attaching an elasticatedmaterial in stretched state or in a partial stretched state to the topsheet or to one or more carrier materials that are then subsequentlyattached to the top sheet. The elastic materials may be in the form of amultitude of strands or a single band with an average thickness (e.g.,gauge) of at least 20 microns, at least 40 microns, or at least 60microns. In some embodiments, the elastic material has an averagethickness up to about 300 microns, up to 200 microns, or up to 150microns. Suitable materials may have an average thickness of about 70 to100 microns. Suitable elastic materials used herein may include VFE-CD,available from Tredegar, and L-86, L-89, or L-90, available from Fulflex(Limerick, Ireland).

The absorbent article 302 may be sag-tolerable and may include a topsheet 311 that is sag-tolerable. This means that the top sheet does notsag when the back sheet and absorbent core sag due to increased weightof the body exudates received by the article. In addition, the top sheetkeeps its z-direction alignment with the anal region and genitals of thewearer, and may also keep its x and y direction alignment. The absorbentarticle (e.g., diaper or training pants) may include a means to ensurethat the top sheet stays in about the same contact or close proximitywith the wearer's anal and/or genital region when the back sheet andcore sag, compared to just after application of the article to thewearer, when the back sheet and core do not yet sag. In someembodiments, the top sheet is sag-tolerable such that when thegeometrical center point of the back sheet is pulled down 4 cm, (i) thetop sheet does not move down more than 0.5 cm, more than 0.25 cm, ordoes not move down at all, and/or (ii) the longitudinal side edges ofthe opening do not move in the x and y direction more than 0.5 cm, morethan 0.25 cm, or do not move at all.

In some embodiments, the top sheet 311 may be sag-tolerable and theretonon-elastically extendable and may have thereto one or more transversefolds and/or longitudinal folds 357, as shown in FIGS. 13-14, in anon-elasticated area 334. In some configurations, the average width ofthe top sheet 311, including the width of the opening 314, may be largerthan the average distance between the longitudinal attachment areas ofthe top sheet 311 to the back sheet 312. In other configurations, theaverage width of the top sheet, including the width of the opening, maybe larger than the average width of the back sheet. As such, the topsheet may, for example, have one or more transverse and/or longitudinalfolds, which can unfold in use and allow sagging of the core and backsheet, while the top sheet remains in place. In some embodiments, thetop sheet 311 with the longitudinal folds 357 is not attached to theabsorbent core 214, but directly to the back sheet 312 with longitudinalattachment lines 323, to ensure that the diaper 302 and the top sheet311 thereof are sag-tolerable.

In one embodiment, the absorbent article 10 may include one more topsheets that facilitate passage of bowel movement through the top sheetsand into the at least one cavity 215. Examples of such top sheets aredescribed in U.S. Patent Application Publication No. 2004/0092900, U.S.Pat. No. 5,342,338, European Patent Application Publication No. 1201212.As described in U.S. Pat. No. 5,342,338 to Roe, the absorbent article 10may include a first top sheet with apertures large enough forlow-viscosity fecal material to pass through it.

The amount of absorbent particulate polymer material 66 and 74 presentin the absorbent core 14 (or 214) may vary, but in certain embodiments,is present in the absorbent core in an amount greater than about 80% byweight of the absorbent core, or greater than about 85% by weight of theabsorbent core, or greater than about 90% by weight of the absorbentcore, or greater than about 95% by weight of the core. In a particularembodiment, the absorbent core 14 (or 214) consists essentially of thefirst and second substrates 64 and 72, the absorbent particulate polymermaterial 66 and 74, and the thermoplastic adhesive composition 68 and76. In an embodiment, the absorbent core 14 (or 214) may besubstantially cellulose free.

In certain embodiments which are not substantially cellulose free, theabsorbent core 14 (or 214) can include some amount of cellulosic fibermaterial, such as airfelt. A relatively low amount of cellulosicmaterial is used, in certain embodiments, which may be less than about40 weight percent, or about 20 weight percent of cellulosic material, ascompared to the weight of absorbent core.

According to certain embodiments, the basis weight of absorbentparticulate polymer material 66 and 74 in at least one freely selectedfirst square measuring 1 cm×1 cm in a zone of greater absorbentparticulate polymer material basis weight may be at least 10%, or 20%,or 30%, 40% or 50% higher than the basis weight of absorbent particulatepolymer material 66 and 74 in at least one freely selected second squaremeasuring 1 cm×1 cm in a zone of lesser absorbent particulate polymermaterial basis weight. In a certain embodiment, the first and the secondsquare are centered about the longitudinal axis.

According to an embodiment, a suitable absorbent particulate polymermaterial 66 and 74, even in the swollen state, i.e., when liquid hasbeen absorbed, does not substantially obstruct the liquid flowthroughout the material, especially when the material has apermeability, as expressed by the saline flow conductivity of theabsorbent polymer material, of greater than about 10, 40, 80, 100, 110,120, 150, or 200×10⁻⁷ cm³·sec/g and a centrifuge retention capacity(CRC) of greater than about 20 g/g, greater than about 25 g/g, or lessthan about 40 g/g, less than about 35 g/g. Saline flow conductivity is aparameter well recognized in the art and is to be measured in accordancewith the test disclosed in U.S. Patent Application Publication No.2007/0219521. Centrifuge retention capacity is another parameter wellrecognized in the art and is to be measured in accordance with the testdisclosed hereinbelow. According to a certain embodiment, the absorbentpolymer material has an Absorption Against Pressure (AAP) of at leastabout 20 g/g, greater than about 23 g/g, or greater than about 25 g/g asmeasured according to the test described below. Absorbent polymermaterials for use in certain embodiments have a basis weight of at leastabout 200 g/m², at least about 400 g/m², or at least about 600 g/m². Tomaintain flexibility the basis weight is desirably less than about 2000g/m².

In certain embodiments wherein the absorbent core 14 (or 214) issubstantially cellulose free, the absorbent core 14 (or 214) has adensity greater than about 0.4 g/m³, greater than about 0.5 g/m³, orgreater than about 0.6 g/m³.

According to an embodiment, the absorbent particulate polymer material66 and 74 may be present in the diaper 10 so as to impart an averagebasis weight of more than about 50, 100, 200, 300, 400, 500, 600, 700,800 or 900 g/m². The diaper 10 (or 302), according to an exemplaryembodiment, may have a relatively narrow crotch width for increasedwearing comfort. The diaper 10 (or 302) may have a crotch width of lessthan about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm or even less than about 50mm. Hence, the absorbent core 14 (or 214), according to an embodiment,may have a crotch width as measured along a transversal line which ispositioned at equal distance to the front edge and the rear edge of thecore which is less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm or evenless than about 50 mm, as measured along a transversal line which ispositioned at equal distance to the front edge and the rear edge of thecore. It has been found that, for most absorbent articles such asdiapers, the liquid discharge occurs predominately in the front half ofthe diaper. The front half of the absorbent core 14 may thereforecomprise most of the absorbent capacity of the core. Thus, according tocertain embodiments, the front half of said absorbent core 14 (or 214)may comprise more than about 60% of the absorbent capacity, or more thanabout 65%, 70%, 75%, 80%, 85%, or 90% of the absorbent capacity.

In certain embodiments, the absorbent core 14 (or 214) may furthercomprise any absorbent material that is generally compressible,conformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining liquids such as urine and other certain bodyexudates. In such embodiments, the absorbent core 14 (or 214) maycomprise a wide variety of liquid-absorbent materials commonly used indisposable diapers and other absorbent articles such as comminuted woodpulp, which is generally referred to as airfelt, creped cellulosewadding, melt blown polymers, including co-form, chemically stiffened,modified or cross-linked cellulosic fibers, tissue, including tissuewraps and tissue laminates, absorbent foams, absorbent sponges, or anyother known absorbent material or combinations of materials. Theabsorbent core 14 (or 214) may further comprise minor amounts (typicallyless than 10%) of non-liquid absorbent materials, such as adhesives,waxes, oils and the like.

Exemplary absorbent structures for use as the absorbent assemblies aredescribed in U.S. Pat. No. 4,610,678 (Weisman et al.); U.S. Pat. No.4,834,735 (Alemany et al.); U.S. Pat. No. 4,888,231 (Angstadt); U.S.Pat. No. 5,260,345 (DesMarais et al.); U.S. Pat. No. 5,387,207 (Dyer etal.); U.S. Pat. No. 5,397,316 (LaVon et al.); and U.S. Pat. No.5,625,222 (DesMarais et al.).

In a certain embodiment best illustrated in FIG. 2, the elasticized legcuffs 24 may comprise absorbent particulate polymer material 66 whichmay be laid down directly of the elasticized legs cuffs 24 in the samemanner as the absorbent particulate polymer material 66 is laid down onfirst substrate 64 (described below) or may be formed on a separatesubstrate and added later.

The thermoplastic material 68 and 76 may serve to cover and at leastpartially immobilize the absorbent particulate polymer material 66 and74. In one embodiment of the present invention, the thermoplasticmaterial 68 and 76 can be disposed essentially uniformly within theabsorbent particulate polymer material 66 and 74. However, in a certainembodiment, the thermoplastic material 68 and 76 may be provided as afibrous layer which is at least partially in contact with the absorbentparticulate polymer material 66 and 74 and partially in contact with thesubstrate layers 64 and 72 of the first and second absorbent layers 60and 62. FIGS. 3, 4, and 7 show such a structure, and in that structure,the absorbent particulate polymer material 66 and 74 is provided as adiscontinuous layer, and a layer of fibrous thermoplastic material 68and 76 is laid down onto the layer of absorbent particulate polymermaterial 66 and 74, such that the thermoplastic material 68 and 76 is indirect contact with the absorbent particulate polymer material 66 and74, but also in direct contact with the second surfaces 80 and 84 of thesubstrates 64 and 72, where the substrates are not covered by theabsorbent particulate polymer material 66 and 74. This imparts anessentially three-dimensional structure to the fibrous layer ofthermoplastic material 68 and 76, which in itself is essentially atwo-dimensional structure of relatively small thickness, as compared tothe extension in length and width directions. In other words, thethermoplastic material 68 and 76 undulates between the absorbentparticulate polymer material 68 and 76 and the second surfaces of thesubstrates 64 and 72.

Thereby, the thermoplastic material 68 and 76 may provide cavities tocover the absorbent particulate polymer material 66 and 74, and therebyimmobilizes this material. In a further aspect, the thermoplasticmaterial 68 and 76 bonds to the substrates 64 and 72 and thus affixesthe absorbent particulate polymer material 66 and 74 to the substrates64 and 72. Thus, in accordance with certain embodiments, thethermoplastic material 68 and 76 immobilizes the absorbent particulatepolymer material 66 and 74 when wet, such that the absorbent core 14achieves a wet immobilization of more than about 50%, or more than about60%, 70%, 80% or 90% according to the Wet Immobilization Test. The WetImmobilization Test is described in U.S. Patent Application PublicationNo. 2004/0162536, the disclosure of which is expressly incorporatedherein by reference. Some thermoplastic materials will also penetrateinto both the absorbent particulate polymer material 66 and 74 and thesubstrates 64 and 72, thus providing for further immobilization andaffixation. According to certain embodiments, the thermoplastic material68 and 76 may have an effective mesh size less than 300 microns.

Of course, while the thermoplastic materials disclosed herein provide amuch improved wet immobilization (i.e., immobilization of absorbentmaterial when the article is wet or at least partially loaded), thesethermoplastic materials may also provide a very good immobilization ofabsorbent material when the absorbent core 14 (or 214) is dry.

According to certain embodiments, the thermoplastic material 68 and 76can comprise any thermoplastic material, including, but not limited toadhesive thermoplastic materials, also referred to as hot meltadhesives. Some initially thermoplastic materials may later lose theirthermoplasticity due to a curing step, e.g., initiated via heat, UVradiation, electron beam exposure or moisture or other means of curing,leading to the irreversible formation of a crosslinked network ofcovalent bonds. Those materials having lost their initial thermoplasticbehavior are herein also understood as thermoplastic materials.

Without wishing to be bound by theory, it has been found that thosethermoplastic materials which are most useful for immobilizing theabsorbent particulate polymer material 66 and 74 combine good cohesionand good adhesion behavior. Good adhesion may promote good contactbetween the thermoplastic material 68 and 76 and the absorbentparticulate polymer material 66 and 74 and the substrates 64 and 72.Good cohesion reduces the likelihood that the adhesive breaks, inparticular in response to external forces, and namely in response tostrain. When the absorbent core 14 (or 214) absorbs liquid, theabsorbent particulate polymer material 66 and 74 swells and subjects thethermoplastic material 68 and 76 to external forces. In certainembodiments, the thermoplastic material 68 and 76 may allow for suchswelling, without breaking and without imparting too many compressiveforces, which would restrain the absorbent particulate polymer material66 and 74 from swelling.

In accordance with certain embodiments, the thermoplastic material 68and 76 may comprise, in its entirety, a single thermoplastic polymer ora blend of thermoplastic polymers, having a softening point, asdetermined by the ASTM Method D-36-95 “Ring and Ball”, in the rangebetween 50° C. and 300° C., or alternatively the thermoplastic materialmay be a hot melt adhesive comprising at least one thermoplastic polymerin combination with other thermoplastic diluents such as tackifyingresins, plasticizers and additives such as antioxidants. In certainembodiments, the thermoplastic polymer has typically a molecular weight(Mw) of more than 10,000 and a glass transition temperature (Tg) usuallybelow room temperature or 0° C.<T_(g)<20° C. In certain embodiments,typical concentrations of the polymer in a hot melt are in the range ofabout 20 to about 40% by weight. In certain embodiments, thermoplasticpolymers may be water insensitive. Exemplary polymers are (styrenic)block copolymers including A-B-A triblock structures, A-B diblockstructures and (A-B)n radial block copolymer structures wherein the Ablocks are non-elastomeric polymer blocks, typically comprisingpolystyrene, and the B blocks are unsaturated conjugated diene or(partly) hydrogenated versions of such. The B block is typicallyisoprene, butadiene, ethylene/butylene (hydrogenated butadiene),ethylene/propylene (hydrogenated isoprene), and mixtures thereof.

Other suitable thermoplastic polymers that may be employed aremetallocene polyolefins, which are ethylene polymers prepared usingsingle-site or metallocene catalysts. Therein, at least one comonomercan be polymerized with ethylene to make a copolymer, terpolymer orhigher order polymer. Also applicable are amorphous polyolefins oramorphous polyalphaolefins (APAO) which are homopolymers, copolymers orterpolymers of C2 to C8 alphaolefins.

In exemplary embodiments, the resin has typically a Mw below 5,000 and aTg usually above room temperature, typical concentrations of the resinin a hot melt are in the range of about 30 to about 60%, and theplasticizer has a low Mw of typically less than 1,000 and a Tg belowroom temperature, with a typical concentration of 0-15%.

In certain embodiments, the thermoplastic material 68 and 76 is presentin the form of fibers. In some embodiments, the fibers will have anaverage thickness of about 1 to about 50 micrometers or about 1 to about35 micrometers and an average length of about 5 mm to about 50 mm orabout 5 mm to about 30 mm. To improve the adhesion of the thermoplasticmaterial 68 and 76 to the substrates 64 and 72 or to any other layer, inparticular any other non-woven layer, such layers may be pre-treatedwith an auxiliary adhesive.

In certain embodiments, the thermoplastic material 68 and 76 will meetat least one, or several, or all of the following parameters:

An exemplary thermoplastic material 68 and 76 may have a storage modulusG′ measured at 20° C. of at least 30,000 Pa and less than 300,000 Pa, orless than 200,000 Pa, or between 140,000 Pa and 200,000 Pa, or less than100,000 Pa. The storage modulus G′ at 20° C. may be a measure for thepermanent “tackiness” or permanent adhesion of the thermoplasticmaterial used. In a further aspect, the storage modulus G′ measured at35° C. may be greater than 100,000 Pa. In a further aspect, the storagemodulus G′ measured at 60° C. may be less than 300,000 Pa and more than18,000 Pa, or more than 24,000 Pa, or more than 30,000Pa, or more than90,000 Pa. The storage modulus measured at 60° C. may be a measure forthe form stability of the thermoplastic material at elevated ambienttemperatures. This value is particularly important if the absorbentproduct is used in a hot climate where the thermoplastic material wouldlose its integrity if the storage modulus G′ at 60° C. is notsufficiently high.

G′ is typically measured using a rheometer as schematically shown inFIG. 11 for the purpose of general illustration only. The rheometer 127is capable of applying a shear stress to the adhesive and measuring theresulting strain (shear deformation) response at constant temperature.The adhesive is placed between a Peltier-element acting as lower, fixedplate 128 and an upper plate 129 with a radius R of e.g., 10 mm, whichis connected to the drive shaft of a motor to generate the shear stress.The gap between both plates has a height H of e.g., 1500 micron. ThePeltier-element enables to control the temperature of the material(+0.5° C.).

In a further embodiment, the thermoplastic material 68 and 76 may have adeformation resistance strain in % between about 20 and about 90.

In a further aspect, the loss angle tan Delta of the adhesive at 60° C.may be below the value of 2, or below the value of 1, or below the valueof 0.5. The loss angle tan Delta at 60° C. is correlated with the liquidcharacter of an adhesive at elevated ambient temperatures. The lower tanDelta, the more an adhesive behaves like a solid rather than a liquid,i.e., the lower its tendency to flow or to migrate and the lower thetendency of an adhesive superstructure as described herein todeteriorate or even to collapse over time. This value is henceparticularly important if the absorbent article is used in a hotclimate.

In a further embodiment, the thermoplastic material 68 and 76 may have aglass transition temperature T_(g) of less than 25° C., or less than 22°C., or less than 18° C., or less than 15° C. A low glass transitiontemperature T_(g) is beneficial for good adhesion. In a furtherembodiment, a low glass transition temperature T_(g) ensures that theadhesive thermoplastic material does not become too brittle.

In a further embodiment, the thermoplastic material 68 and 76 may havean elasticity factor from about 10 to about 20.

In yet a further embodiment, the thermoplastic material 68 and 76 mayhave a sufficiently high cross-over temperature. A sufficiently highcross-over temperature T_(x) has been found beneficial for hightemperature stability of the thermoplastic layer and hence it ensuresgood performance of the absorbent product and in particular good wetimmobilization even under conditions of hot climates and hightemperatures. Therefore, T_(x) may be above 80° C., or above 85° C.,above 90° C., or above 95° C.

As described hereinabove, the absorbent core 14 (or 214) may alsocomprise an auxiliary adhesive layer 69. The auxiliary adhesive may bedeposited on the first and second substrates 64 and 72 of the respectivefirst and second absorbent layers 60 and 62 before application of theabsorbent particulate polymer material 66 and 74 for enhancing adhesionof the absorbent particulate polymer materials 66 and 74 and thethermoplastic material 68 and 76 to the respective substrates 64 and 72.The auxiliary glue 69 may also aid in immobilizing the absorbentparticulate polymer material 66 and 74 and may comprise the samethermoplastic material as described hereinabove or may also compriseother adhesives including but not limited to sprayable hot meltadhesives, such as H.B. Fuller Co. (St. Paul, Minn.) Product No.HL-1620-B. The auxiliary glue may be applied to the substrates 64 and 72by any suitable means, but according to certain embodiments, may beapplied in about 0.5 to about 1 mm wide slots spaced about 0.5 to about2 mm apart.

The cover layer 70 shown in FIG. 4 may comprise the same material as thesubstrates 64 and 72, or may comprise a different material. In certainembodiments, suitable materials for the cover layer 70 are the non-wovenmaterials, typically the materials described above as useful for thesubstrates 64 and 72.

In a certain embodiment not illustrated, the absorbent core 14 (or 214)may be wrapped by a core wrap material. In one embodiment, the core wrapmaterial comprises a top layer and a bottom layer. The core wrapmaterial, the top layer or the bottom layer may be provided from anon-woven material. Such a core wrap may be provided from two or moreseparate sheets of materials or they may be alternatively provided froma unitary sheet of material. A unitary sheet of material may be wrappedaround the storage layer 60, e.g., in a C-fold.

In a certain embodiment, the absorbent core 214 is substantiallycellulose free. In this embodiment, the cavity 215 advantageouslyprovides a void volume for the fecal matter even when the absorbent coreis already liquid, e.g., urine) loaded. Moreover, it provides bowelmovement distribution toward the back of the diaper, away from thewearer's genitals, providing easier clean up. In an embodiment with anelasticized top sheet 311, the cavity 215 advantageously works as aspace between the absorbent core 214 and the elasticized top sheet 311,so that the bowel movement is directed underneath the top sheet. Inaddition, in an embodiment where there is little or no absorbentparticulate polymer material at the bottom of the cavity, when a bowelmovement gets into the cavity, it becomes visible from the outsidethrough the back sheet. This advantageously may serve as a positivesignaling function for the caretaker of the wearer to check/change thediaper or training pant.

In one embodiment, the visibility of the at least one cavity 215 isenhanced by the inclusion of a color, print, pattern, or a combinationthereof, in one or more layers of the absorbent article. For example, inone case, the cavity may be made more visible by including a colored(i.e., non-white) layer below the cavity, such that the color can beseen in the cavity due to the lower (or zero) basis weight in thatregion of the absorbent core. In another embodiment, a colored layer maybe added over top of the cavity, e.g., the core cover, top sheet, or asa new, additional layer.

Method and Apparatus for Making Absorbent Articles

A printing system 130 for making an absorbent core 14 in accordance withan embodiment of this invention is illustrated in FIG. 16 and maygenerally comprise a first printing unit 132 for forming the firstabsorbent layer 60 of the absorbent core 14 and a second printing unit134 for forming the second absorbent layer 62 of the absorbent core 14.It is understood throughout the following description that this systemwould be equally applicable to the making of absorbent core 214.

The first printing unit 132 may comprise a first auxiliary adhesiveapplicator 136 for applying an auxiliary adhesive 69 to the substrate64, which may be a nonwoven web, a first rotatable support roll 140 forreceiving the substrate 64, a hopper 142 for holding absorbentparticulate polymer material 66, a printing roll 144 for transferringthe absorbent particulate polymer material 66 to the substrate 64, and athermoplastic material applicator 146 for applying the thermoplasticmaterial 68 to the substrate 64 and the absorbent particulate polymer 66material thereon.

The second printing unit 134 may comprise a second auxiliary adhesiveapplicator 148 for applying an auxiliary adhesive 73 to the secondsubstrate 72, a second rotatable support roll 152 for receiving thesecond substrate 72, a second hopper 154 for holding the absorbentparticulate polymer material 74, a second printing roll 156 fortransferring the absorbent particulate polymer material 74 from thehopper 154 to the second substrate 72, and a second thermoplasticmaterial applicator 158 for applying the thermoplastic material 76 tothe second substrate 72 and the absorbent particulate polymer material74 thereon.

The printing system 130 also includes a guide roller 160 for guiding theformed absorbent core from a nip 162 between the first and secondrotatable support rolls 140 and 152.

The first and second auxiliary applicators 136 and 148 and the first andsecond thermoplastic material applicators 146 and 158 may be a nozzlesystem which can provide a relatively thin but wide curtain ofthermoplastic material.

Turning to FIG. 17, portions of the first hopper 142, first support roll140, and first printing roll 144 are illustrated. As also shown in FIG.20, the first rotatable support roll 140, which has the same structureas the second rotatable support roll 152, comprises a rotatable drum 164and a peripheral vented support grid 166 for receiving the firstsubstrate 64.

As also illustrated in FIG. 18, the first printing roll 144, which hasthe same structure as the second printing roll 156, comprises arotatable drum 168 and a plurality of absorbent particulate polymermaterial reservoirs 170 and 171 in a peripheral surface 172 of the drum168. The reservoirs 170 and 171, best illustrated in FIG. 19, may have avariety of shapes, including cylindrical, conical, or any other shape.The reservoirs 170 and 171 may lead to an air passage 174 in the drum168 and comprise a vented cover 176 for holding adhesive particulatepolymer material 66 in the reservoir and preventing the adhesiveparticulate polymer material 66 from falling or being pulled into theair passage 174.

The first printing roll 144 is designed to produce a certain embodimentlike the absorbent core 14 illustrated in FIG. 5 wherein side absorbentzones 120 and 122 have a higher basis weight of absorbing particulatepolymer material 66 and 74 than the central absorbent zone 121. In theembodiment illustrated in FIG. 19, this effect may be achieved by havinga corresponding set of reservoirs 170 which are relatively deep and asecond set 171 of reservoirs which are relatively shallow, such that thedeeper reservoirs 170 carry more absorbent particulate polymer materialand deliver more absorbent particulate polymer material 66 to the sideabsorbent zones 120 and 122 and the more shallow reservoirs 171 holdless adhesive particulate polymer material and deliver less absorbentparticulate polymer material 66 to the central zone 121 of the absorbentcore 14. The sets of deeper and shallower reservoirs 170 and 171, ofcourse, can be arranged in any variety of patterns to define the cavity215 of absorbent core 214, as well as in configurations to create anabsorbent core with any corresponding variety of varying absorbentparticulate polymer material basis weights across the absorbent core214. FIG. 19, in particular, illustrates the difference in volumetricsizes of first and second sets of reservoirs 170 and 171.

Other methods of forming the cavity and delivering a varying profile ofabsorbent particulate polymer basis weights to the absorbent core 14 or214 include, but are not limited to, applying a higher vacuum insections of the first and second rotatable support rolls 140 and 152where more absorbent particulate polymer material is desired or, whenthe absorbent particulate polymer material is delivered to the absorbentcore substrate 64 pneumatically, such as when combining cellulosicfibers with absorbent particulate polymer material, directing the airstream carrying the absorbent particulate polymer material andcellulosic fibers to areas of the absorbent core substrate where ahigher basis weight of absorbent particulate polymer material isdesired.

In operation, the printing system 130 receives the first and secondsubstrate 64 and 72 into the first and second printing units 132 and134, respectively, the first substrate 64 is drawn by the rotating firstsupport roll 140 past the first auxiliary adhesive applicator 136 whichapplies the first auxiliary adhesive to the first substrate 64 in apattern such as described hereinabove. A vacuum (not shown) within thefirst support roll 140 draws the first substrate 64 against the verticalsupport grid 166 and holds the first substrate 64 against the firstsupport roll 140. This presents an uneven surface on the first substrate64. Due to gravity, or by using the vacuum means, the substrate 64 willfollow the contours of the uneven surface and thereby the substrate 64will assume a mountain and valley shape. The absorbent particulatepolymer material 66 may accumulate in the valleys presented by thesubstrate 64. The first support roll 140 then carries the firstsubstrate 64 past the rotating first printing roll 144 which transfersthe absorbent particulate polymer material 66 from the first hopper 142to the first substrate 64 in the grid pattern 92 which is bestillustrated in FIGS. 5 and 6. A vacuum (not shown) in the first printingroll 144 may hold the absorbent particulate polymer material 66 in thereservoirs 170 until time to deliver the absorbent particulate polymermaterial 66 to the first substrate 64. The vacuum may then be releasedor air flow through the air passages 174 may be reversed to eject theabsorbent particulate polymer material 66 from the reservoirs and ontothe first substrate 64. The absorbent particulate polymer material 66may accumulate in the valleys presented by the substrate 64. The supportroll 140 then carries the printed first substrate 64 past thethermoplastic material applicator 136 which applies the thermoplasticmaterial 68 to cover the absorbent particulate polymer material 66 onthe first substrate 64.

Hence, the uneven surface of the vented support grid 166 of the supportrolls 140 and 152 determines the distribution of absorbent particulatepolymeric material 66 and 74 throughout the absorbent core 14 andlikewise determines the pattern of junction areas 96.

Meanwhile, the second rotatable support roll draws the second substrate72 past the second auxiliary adhesive applicator 148 which applies anauxiliary adhesive to the second substrate 72 in a pattern such as isdescribed hereinabove. The second rotatable support roll 152 thencarries the second substrate 72 past the second printing roll 156 whichtransfers the absorbent particulate polymer material 74 from the secondhopper 154 to the second substrate 72 and deposits the absorbentparticulate polymer material 74 in the grid pattern 92 on the secondsubstrate 72 in the same manner as described with regard to the firstprinting unit 132 above. The second thermoplastic material applicator158 then applies the thermoplastic material 76 to cover the absorbentparticulate polymer material 74 on the second substrate 72. The printedfirst and second substrates 64 and 72 then pass through the nip 162between the first and second support rolls 140 and 152 for compressingthe first absorbent layer 60 and second absorbent layer 62 together toform the absorbent core 14.

In an optional further process step a cover layer 70 may be placed uponthe substrates 64 and 72, the absorbent particulate polymer material 66and 74, and the thermoplastic material 68 and 76. In another embodiment,the cover layer 70 and the respective substrate 64 and 72 may beprovided from a unitary sheet of material. The placing of the coverlayer 70 onto the respective substrate 64 and 72 may then involve thefolding of the unitary piece of material.

FIGS. 21-23 illustrate certain embodiments of printing rolls 144′ and144″ for making corresponding embodiments of absorbent cores 14′ and 14″illustrated in FIGS. 9 and 10, respectively. As shown in FIGS. 21 and22, the printing roll 144′ for making the absorbent core 14′ illustratedin FIG. 9 comprises sets of deeper and shallower reservoirs 170′ and171′ for forming the end absorbent zones 123 and 124, which have ahigher absorbent particulate polymer material basis weight, and thecentral absorbent zone 125, which has a lower absorbent particulatepolymer material basis weight, respectively. Likewise, the printing roll144″ has sets of deeper and shallower reservoirs 170″ and 171″,respectively, for forming the side absorbent zones 120′ and 122′ and endabsorbent zones 123′ and 124′, having a higher basis weight of absorbentparticulate polymer material, and the central zone 121′ and 125′ havinga lower basis weight of absorbent particulate polymer material. Thistechnique of profiling the absorbent particulate polymer material inboth the MD and CD may be readily adapted to form a cavity, defined atleast in part by the lower basis weight of absorbent particulate polymermaterial in an elongated central region.

Absorbent articles such as the diapers 10 made in accordance withembodiments of this invention may be folded and packaged fordistribution and sale. Absorbent articles are typically bi-folded, butmay also be tri-folded. After folding, the folded absorbent articles maybe stacked to form a stack comprising a plurality of absorbent articles.The stack may then be compressed and encased in a packaging materialsuch as a bag, a pouch, a box, or the like.

All patents and patent applications (including any patents which issuethereon) assigned to the Procter & Gamble Company referred to herein arehereby incorporated by reference to the extent that it is consistentherewith.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A disposable absorbent article comprising: achassis including a top sheet and a back sheet; and an absorbent corelocated between the top sheet and the back sheet and comprisingabsorbent particulate polymer material, wherein the absorbent core issubstantially cellulose free and comprises at least one cavity having aperimeter partially defined by the absorbent particulate polymermaterial.
 2. The disposable absorbent article of claim 1, wherein the atleast one cavity has a void volume from about 2 ml in a dry state toabout 70 ml in a saturated state.
 3. The disposable absorbent article ofclaim 1, wherein the absorbent particulate polymer material present inthe absorbent core has a basis weight that varies across the absorbentcore in a direction substantially perpendicular to a centrallongitudinal axis, in a direction substantially parallel to the centrallongitudinal axis, or in both directions.
 4. The disposable absorbentarticle of claim 1, wherein the at least one cavity is substantiallyfree of absorbent particulate polymer material.
 5. The disposableabsorbent article of claim 1, further comprising a central longitudinalaxis extending from a first end to a second end, wherein the at leastone cavity comprises (i) a first channel elongated in a directionsubstantially parallel to and located about the central longitudinalaxis, and (ii) a second channel elongated in a direction substantiallyperpendicular to the central longitudinal axis.
 6. The disposableabsorbent article of claim 5, wherein the first and second channels ofthe cavity together form a T-shape.
 7. The disposable absorbent articleof claim 6, wherein the first channel has a width from about 5% to about60% of a width of the absorbent core and a length from about 2% to about50% of a length of the absorbent core.
 8. The disposable absorbentarticle of claim 6, wherein the second channel has a width from about25% to about 90% of a width of the absorbent core and a length fromabout 2% to about 40% of a length of the absorbent core.
 9. Thedisposable absorbent article of claim 6, wherein the first channel ofthe cavity has a width between about 10 mm and about 40 mm, and a lengthbetween about 10 mm and about 130 mm.
 10. The disposable absorbentarticle of claim 6, wherein the second channel of the cavity has a widthbetween about 30 mm and about 110 mm, and a length between about 10 mmand about 100 mm.
 11. The disposable absorbent article of claim 1,wherein the absorbent core comprises a core cover and a dusting layeradhered to one another about a periphery of the absorbent core to forman envelope about the absorbent particulate polymer materials to holdthe absorbent particulate polymer material within the absorbent core.12. The disposable absorbent article of claim 11, wherein the core coverand the dusting layer are adhered to one another about an area defininga bottom of the at least one cavity.
 13. The disposable absorbentarticle of claim 1, further comprising an acquisition system locatedbetween the absorbent core and the top sheet.
 14. The disposableabsorbent article of claim 13, wherein the acquisition system comprisesan upper acquisition layer, which faces the top sheet, and a loweracquisition layer, which faces the absorbent core and which does notcover the at least one cavity.
 15. The disposable absorbent article ofclaim 14, wherein the upper acquisition layer does not completely coverthe at least one cavity.
 16. The disposable absorbent article of claim13, wherein the perimeter of the at least one cavity is further definedby interior edges of an aperture in the acquisition system.
 17. Thedisposable absorbent article of claim 1, wherein the top sheet is anelasticized top sheet having at least one opening, at least a portion ofwhich opening is substantially aligned with the at least one cavity inthe absorbent core.
 18. The disposable absorbent article of claim 1,wherein the disposable absorbent article is a diaper or a pant.
 19. Thedisposable absorbent article of claim 18, wherein the at least onecavity is located in the absorbent core along the central longitudinalaxis of the diaper or pant at a position which, when the diaper or pantis worn by a wearer, will be in alignment with a predetermined regionabout the anus of the wearer.